Driver attitude detection system

ABSTRACT

A driver attitude detection system for a vehicle includes a forward facing imaging sensor for capturing image data of a scene occurring forwardly of and in the direction of forward travel of an equipped vehicle. An image processor is operable to process image data captured by the forward facing imaging sensor. A control, responsive at least in part to image processing by the image processor of the captured image data, is operable to determine driver performance and generate a control output indicative of driver performance. The driver attitude detection system may include at least one monitoring device for monitoring a vehicle characteristic of the equipped vehicle, and the control may, responsive at least in part to the at least one monitoring device, be operable to determine driver performance and generate the control output.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. patent applicationSer. No. 12/617,833, filed Nov. 13, 2009, now U.S. Pat. No. 7,859,738,which is a continuation of U.S. patent application Ser. No. 12/122,102,filed May 16, 2008, now U.S. Pat. No. 7,636,188, which is a continuationof U.S. patent application Ser. No. 11/912,576, filed Oct. 25, 2007, nowU.S. Pat. No. 7,626,749, which is a 371 national phase application ofPCT Application No. PCT/US2006/018567, filed May 16, 2006, which claimsthe benefit of U.S. provisional applications Ser. No. 60/783,496, filedMar. 17, 2006; Ser. No. 60/774,449, filed Feb. 17, 2006; Ser. No.60/750,199, filed Dec. 14, 2005; Ser. No. 60/730,334, filed Oct. 26,2005; Ser. No. 60/695,149, filed Jun. 29, 2005; Ser. No. 60/690,400,filed Jun. 14, 2005; and Ser. No. 60/681,250, filed May 16, 2005, whichare all hereby incorporated herein by reference in their entireties.

FIELD OF THE INVENTION

The present invention relates to rearview mirror assemblies and, moreparticularly, to an interior or exterior rearview mirror assembly havinginformation displayed at the mirror assembly.

BACKGROUND OF THE INVENTION

Interior and exterior mirrors for vehicles typically comprise asubstrate having a first surface facing a viewer of the mirror and asecond, reflecting surface opposite the first surface. Often, suchmirrors may comprise electro-optic reflective element assemblies, whichhave first and second substrates, whereby the reflecting surface istypically at the third surface of the reflective element assembly (thefront surface of the rear substrate) or at the fourth surface of thereflective element assembly (the rear surface of the rear substrate). Itis common to include information created on the reflective elementsubstrate, such as safety messages (for example, an exterior rearviewmirror may include the message “objects in mirror are closer than theyappear” or the like) or other information or indicia. Examples of suchindicia are described in U.S. Pat. Nos. 5,189,537 and 5,825,527, whichare hereby incorporated herein by reference in their entireties.

Such indicia or information is typically created by removal of thereflective coating or layers at the respective surface of the substrate,such as by sand blasting or laser ablating the reflective coating, or byoverlaying or overcoating a material onto one of the layers or coatings,such as by screening of materials, such as ink or epoxy, onto the layersor coatings at the respective substrate surface (such as described inU.S. Pat. No. 5,189,537, which is hereby incorporated herein byreference). Such indicia or information thus provides a marked, highlyvisible and definite indicia or information conveyance that is readilydiscernible and viewable by a person viewing the mirror assembly.

SUMMARY OF THE INVENTION

The present invention provides a display of information or indicia at areflective element by applying or disposing or otherwise forming orestablishing indicia or the like by establishing a layer of a materialthat is different from the reflective material that is coated on therespective substrate to define the reflective surface of the reflectiveelement (such as a layer of reflective material that has a distinctlyhigher or lower reflectivity than that of the layer of reflectivematerial it is coated over or under). The indicia or information isvisible to the viewer of the mirror assembly without unduly detractingfrom or interfering with the functionality of the reflective element.

According to an aspect of the present invention, a rearview minorassembly for a vehicle includes a reflective element having a substratewith a reflective coating thereon. A layer of material is established toform indicia or information at the reflective element. The layer ofmaterial provides a visible contrast between the reflective coating andthe layer of material so that the indicia or information is viewable bya person viewing the minor assembly. The reflective element reflectslight incident thereon over the coated surface, including the area atwhich the layer of material is disposed, and the indicia so created(such as for example, a vehicle brand name or logo) is subtly visible tothe viewer by contrast with the adjacent main reflector coatingreflective property, so that the presence of the indicia or logo isvisible but subtle and non-obtrusive.

The layer of material may comprise a reflective material or atransparent material, and may be discernible due to a contrast in coloror reflectance or due to an interference effect or difference inrefractive index or the like. The reflective element may comprise anelectro-optic reflective element assembly or cell, such as anelectrochromic reflective element or cell, and may have the reflectivecoating at the third or fourth surface of the cell (the front surface ofthe rear substrate or the rear surface of the rear substrate). The layerof material may be disposed or established over the reflective coatingor under the reflective coating. The layer of material may beestablished to provide indicia or a logo or the like, or to provide aninformation message or the like at the mirror reflective element. Theinvention may also be applicable to non-electro optic mirrors such asconventional chromium or titanium mirror reflectors or to blue mirrorreflectors (as are commonly known in the automotive mirror art).

Therefore, the present invention provides a mirror reflective elementthat includes an information message or indicia established at thereflective element that does not unduly detract from or interfere withthe functionality of the reflective element. The reflective elementprovides a desired amount of reflectance of visible light incidentthereon over the reflective area of the mirror, including the area orregion that includes the indicia or information, maintaining at leastabout 35 percent reflectivity (as measured using SAE J964a), morepreferably at least about 40 percent reflectivity, and most preferablyat least about 45 percent reflectivity, in the region or regions wherethe indicia is established. The reflective element and indicia layerthus provide a watermark-type effect at the reflective element, whichallows the vehicle manufacturer or mirror manufacturer to provide abrand name or emblem or logo or the like at the reflective elementwithout unduly affecting the reflectance of the reflective element overthe viewable reflective surface of the reflective element.

These and other objects, advantages, purposes and features of thepresent invention will become apparent upon review of the followingspecification in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front elevation of a reflective element of a rearview mirrorassembly in accordance with the present invention;

FIG. 2 is a rear elevation of the reflective element of FIG. 1;

FIG. 3 is a sectional view of a reflective element of the presentinvention;

FIG. 4 is a sectional view of a rear substrate of a reflective elementof the present invention;

FIG. 5 is a sectional view of another rear substrate of a reflectiveelement of the present invention;

FIG. 6 is a sectional view of a reflective element of the presentinvention;

FIG. 6A is a sectional view of another reflective element of the presentinvention;

FIG. 6B is a sectional view of another reflective element of the presentinvention;

FIG. 7 is a sectional view of another reflective element of the presentinvention, with a display element at a patterned element at the fourthsurface of the reflective element;

FIG. 8 is a sectional view of another reflective element of the presentinvention, with a display element at a transflective element at thefourth surface of the reflective element;

FIG. 9 is a sectional view of another reflective element of the presentinvention, with a display element module at the fourth surface of thereflective element;

FIG. 10A is a sectional view of another reflective element of thepresent invention, with a display element at the rear of the reflectiveelement;

FIG. 10B is a plan view of the display element of FIG. 10A;

FIG. 10C is a sectional view of the display element of FIGS. 10A and10B;

FIG. 10D is a sectional view of another reflective element of thepresent invention, with a display element at the rear of a transflectiveelectro-optic reflective element;

FIG. 10E is a sectional view of another reflective element of thepresent invention, with a display element at the rear of anon-electro-optic reflective element;

FIG. 10F is a plan view of the display element of FIG. 10E;

FIG. 10G is a sectional view of the display element of FIGS. 10E and10F;

FIG. 10H is a sectional view of another reflective element of thepresent invention, with a display element at the rear of a transflectiveelectro-optic reflective element;

FIG. 10I is a sectional view of another reflective element of thepresent invention, with a display element at the rear of a transflectivereflective element;

FIG. 11 is a plan view of another reflective element of the presentinvention;

FIG. 12 is a plan view of another reflective element of the presentinvention, with a wide angle mirror portion;

FIG. 13 is a sectional view of the wide angle mirror portion of thereflective element of FIG. 12;

FIG. 14 is a sectional view of a curved non-electro-optic reflectiveelement of the present invention;

FIG. 15A is a plan view of a non-electro-optic reflective element havinga perimeter band formed thereon in accordance with the presentinvention;

FIG. 15B is a sectional view of the non-electro-optic reflective elementof FIG. 15A;

FIG. 16 is a plan view of another non-electro-optic reflective elementhaving a perimeter band formed thereon in accordance with the presentinvention;

FIG. 17 is a perspective view of a rear substrate of a mirror reflectiveelement for an exterior rearview mirror of the present invention, asviewed from the front or third surface of the rear substrate;

FIG. 18 is a perspective view of the rear substrate of FIG. 17, asviewed from the rear or fourth surface of the rear substrate;

FIG. 19 is a sectional view of the rear substrate of FIGS. 17 and 18,with the third and fourth surface wrap-around coatings thereon;

FIG. 20 is a perspective view of the rear substrate of FIGS. 17-19, asviewed from the front or third surface of the rear substrate, andshowing the transflective mirror layer or layers disposed thereon;

FIG. 21 is a sectional view of a mirror reflective element,incorporating the rear substrate of FIG. 20 in accordance with thepresent invention;

FIG. 22 is a sectional view of another mirror reflective element inaccordance with the present invention;

FIG. 23 is a graph depicting optical properties of a coated rearsubstrate in accordance with the present invention;

FIG. 24 is a graph depicting optical properties of a mirror cell inaccordance with the present invention;

FIG. 25 is a graph depicting optical properties of a coating of thepresent invention;

FIG. 26 is a table listing the initial performance characteristics ofsamples of electrochromic cells in accordance with the presentinvention;

FIG. 27 is a table similar to the table of FIG. 26, but listing theperformance characteristics of the samples after 50,000 cycles;

FIG. 28 is a sectional view of a reflective element assembly inaccordance with the present invention;

FIG. 29 is a sectional view of another reflective element assembly inaccordance with the present invention;

FIG. 30 is a partial sectional view of a mirror assembly in accordancewith the present invention;

FIG. 30A is another partial sectional view of the mirror assembly ofFIG. 30;

FIG. 30B is a partial sectional view of another mirror assembly inaccordance with the present invention;

FIG. 31 is a rear plan view of a reflective element assembly of thepresent invention;

FIG. 32 is a perspective view of another mirror reflective elementassembly in accordance with the present invention; and

FIG. 33 is front plan view of another mirror reflective element assemblyin accordance with the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings and the illustrative embodiments depictedtherein, a reflective element 10 (FIGS. 1 and 2) for a rearview mirrorassembly, such as for an interior or exterior rearview mirror assemblyfor a vehicle, may comprise an electro-optic reflective element assemblyor cell, such as an electrochromic reflective element or cell. Thereflective element 10 includes a front substrate 12 and a rear substrate14 (FIGS. 1-3). The rear reflective element substrate 14 is spaced fromfront reflective element substrate 12, and the cell includes anelectrolyte or monomer composition or electrochromic medium 16 andconductive or semi-conductive layers 18, 20 (described below) sandwichedtherebetween. An epoxy seal material 22 or the like, is applied betweenthe substrates to define the cavity for the electrochromic medium and toadhere the substrates together. Reflective element assembly 10 includesa reflectant indicia layer 24 disposed or otherwise formed at the rearsurface 12 a of the front substrate 12 or the front surface 14 a of rearsubstrate 14, whereby the reflectant indicia layer 24 is viewablethrough the front substrate 12 by a driver of the vehicle, yet does notinterfere with the reflectance of the reflective element assembly.

The rearview mirror assembly may comprise an electro-optic orelectrochromic reflective element or cell, such as an electrochromicmirror assembly and electrochromic reflective element utilizingprinciples disclosed in commonly assigned U.S. Pat. Nos. 6,690,268;5,140,455; 5,151,816; 6,178,034; 6,154,306; 6,002,544; 5,567,360;5,525,264; 5,610,756; 5,406,414; 5,253,109; 5,076,673; 5,073,012;5,117,346; 5,724,187; 5,668,663; 5,910,854; 5,142,407; 4,824,221;5,818,636; 6,166,847; 6,111,685; 6,392,783; 6,710,906; 6,798,556;6,554,843 and/or 4,712,879, and/or U.S. patent application Ser. No.10/054,633, filed Jan. 22, 2002, now U.S. Pat. No. 7,195,381; and/orSer. No. 11/021,065, filed Dec. 23, 2004, now U.S. Pat. No. 7,255,451,and/or International Pat. Publication Nos. WO 2004/098953, publishedNov. 18, 2004; WO 2004/042457, published May 21, 2004; and WO2003/084780, published Oct. 16, 2003, which are all hereby incorporatedherein by reference in their entireties, and/or as disclosed in thefollowing publications: N. R. Lynam, “Electrochromic AutomotiveDay/Night Mirrors”, SAE Technical Paper Series 870636 (1987); N. R.Lynam, “Smart Windows for Automobiles”, SAE Technical Paper Series900419 (1990); N. R. Lynam and A. Agrawal, “Automotive Applications ofChromogenic Materials”, Large Area Chromogenics: Materials and Devicesfor Transmittance Control, C. M. Lampert and C. G. Granquist, EDS.,Optical Engineering Press, Wash. (1990), which are hereby incorporatedby reference herein in their entireties. The thicknesses and materialsof the coatings on the substrates of the electrochromic reflectiveelement, such as on the third surface of the reflective elementassembly, may be selected to provide a desired color or tint to themirror reflective element, such as a blue colored reflector, such as isknown in the art and/or such as described in U.S. Pat. Nos. 5,910,854and 6,420,036, and in PCT Application No. PCT/US03/29776, filed Sep. 9,2003 by Donnelly Corp. et al. for MIRROR REFLECTIVE ELEMENT ASSEMBLY,which are all hereby incorporated herein by reference in theirentireties.

Optionally, use of an elemental semiconductor minor, such as a siliconmetal mirror, such as disclosed in U.S. Pat. Nos. 6,286,965; 6,196,688;5,535,056; 5,751,489; and 6,065,840, and/or in U.S. patent applicationSer. No. 10/993,302, filed Nov. 19, 2004, now U.S. Pat. No. 7,338,177,which are all hereby incorporated herein by reference in theirentireties, can be advantageous because such elemental semiconductorminors (such as can be formed by depositing a thin film of silicon) canbe greater than 50 percent reflecting in the photopic (SAE 3964ameasured), while being also substantially transmitting of light (up to20 percent or even more). Such silicon minors also have the advantage ofbeing able to be deposited onto a flat glass substrate and to be bentinto a curved (such as a convex or aspheric) curvature, which is alsoadvantageous since many passenger-side exterior rearview mirrors arebent or curved.

As shown in FIG. 3, the rear surface 12 a of front substrate 12 may havea transparent conductive layer 18 disposed thereon. The transparentconductive layer 18 may comprise any suitable transparent conductivecoating or layer, such as an indium tin oxide (ITO) or doped (antimonyor fluorine doped) tin oxide or doped zinc oxide (such as aluminum-dopedzinc oxide) or an ITO/thin Ag/ITO stack or an ITO/thin Al/ITO stack or athin (preferably, less than about 200 angstroms in physical thickness;more preferably less than about 150 angstroms thick; most preferablyless than about 125 angstroms thick; and greater than about 75 angstromsthick, more preferably greater than about 85 angstroms thick and mostpreferably greater than about 100 angstroms thick) coating of silver (ora silver alloy) sandwiched between ITO or doped zinc oxide layers or athin coating of aluminum (or an aluminum alloy) sandwiched between ITOor doped zinc oxide layers or a thin coating of platinum or palladium(or an alloy thereof) sandwiched between ITO or doped zinc oxide layersor a thin coating of ruthenium (or a ruthenium alloy) sandwiched betweenITO or doped zinc oxide layers, or such as the conductive layersdescribed in U.S. Pat. Nos. 6,690,268; 5,668,663; 5,142,406; 5,442,478and 5,724,187, and/or in U.S. patent application Ser. No. 10/054,633,filed Jan. 22, 2002, now U.S. Pat. No. 7,195,381; Ser. No. 11/021,065,filed Dec. 23, 2004, now U.S. Pat. No. 7,255,451; Ser. No. 10/528,269,filed Mar. 17, 2005, now U.S. Pat. No. 7,274,501; Ser. No. 10/533,762,filed May 4, 2005, now U.S. Pat. No. 7,184,190, and/or in PCTApplication No. PCT/US03/29776, filed Sep. 19, 2003 by Donnelly Corp. etal. for MIRROR REFLECTIVE ELEMENT ASSEMBLY; and/or PCT Application No.PCT/US03/35381, filed Nov. 5, 2003 by Donnelly Corp. et al. forELECTRO-OPTIC REFLECTIVE ELEMENT ASSEMBLY, which are hereby incorporatedherein by reference in their entireties. Note that double-silver stacks(as such term is commonly known and used in the heat mirror-coated art)may be used as a transparent conductor layer. Transparent conductorlayers useful in the present invention thus may comprise conductivematerial such as tin oxide (SnO₂) doped with antimony or fluorine,indium oxide, indium oxide and tin (In₂O₃Sn) (preferably 5-15 percentSn), zinc oxide (ZnO), zinc oxyfluoride, zinc oxide and indium (ZnO:In),zinc oxide and aluminum (ZnO:Al), cadmium stannate (Cd₂SnO₄), cadmiumstannite (CdSnO₃), cadmium oxide (CdO), copper sulfide (Cu₂S), titaniumnitride (TiN), or titanium oxynitride (TiO_(x)N_(1-x)) to provideelectrical contact to the electrochromic medium and/or for otherlayers/elements useful in the present invention.

In the illustrated embodiment, the reflective element 10 comprises athird surface reflective element, and the front surface 14 a of rearsubstrate 14 includes a metallic reflective layer or coating or coatings20 disposed thereon. The metallic reflective coatings 20 may compriseany suitable metallic layer or layers, such as silver or chromium orrhodium or aluminum or the like, and/or such as the layer or layers ofthe types described in U.S. Pat. Nos. 6,690,268; 5,668,663 and5,724,187, and/or in U.S. patent application Ser. No. 10/054,633, filedJan. 22, 2002, now U.S. Pat. No. 7,195,381; Ser. No. 11/021,065, filedDec. 23, 2004, now U.S. Pat. No. 7,255,451; Ser. No. 10/528,269, filedMar. 17, 2005, now U.S. Pat. No. 7,274,501; Ser. No. 10/533,762, filedMay 4, 2005, now U.S. Pat. No. 7,184,190, and/or in PCT Application No.PCT/US03/29776, filed Sep. 19, 2003 by Donnelly Corp. et al. for MIRRORREFLECTIVE ELEMENT ASSEMBLY; and/or PCT Application No. PCT/US03/35381,filed Nov. 5, 2003 by Donnelly Corp. et al. for ELECTRO-OPTIC REFLECTIVEELEMENT ASSEMBLY, which are hereby incorporated herein by reference intheir entireties.

As shown in FIG. 3, the indicia reflector or indicia layer 24 may bedisposed or established over a portion of the third surface metallicconductive layer 20. For example, the metallic reflective layer maycomprise silver or aluminum or the like or alloys thereof, and mayprovide at least approximately 80 percent or more reflectivity of lightincident thereon. The indicia metallic reflector 24 may comprise ametallic material that has a reduced reflectivity of light incidentthereon as compared to the reflectivity of the metallic reflective layer20. For example, the indicia metallic reflector 24 may comprise chromiumor titanium or the like or alloys thereof, and thus may, providereflectivity in the range of approximately 35 percent to approximately65 percent. The reduced reflectivity of light incident on the indiciametallic reflector 24 provides a contrast between the indicia reflectorand the reflective coating 20, such that the indicia metallic reflectoris discernible by a person viewing the reflective element, yet stillprovides reflectivity at the indicia area so as to not unduly affect thefunctionality of the reflective element. Optionally, the indiciareflector may comprise a dielectric coating, such as a transparentconductive coating, such as an ITO or doped tin oxide or doped zincoxide (such as with an aluminum dopant) or the like, whereby theinterference effect caused by the ITO adds a slight but discerniblecolor tint at the indicia reflector so that the indicia is discernibleby a person viewing the reflective element, yet still providesreflectivity at the indicia area so as to not unduly affect thefunctionality of the reflective element. Examples of variousinterference effects of ITO or other transparent conductive materialsare described in PCT Application No. PCT/US03/29776, filed Sep. 19, 2003by Donnelly Corp. et al. for MIRROR REFLECTIVE ELEMENT ASSEMBLY; and/orPCT Application No. PCT/US03/35381, filed Nov. 5, 2003 by Donnelly Corp.et al. for ELECTRO-OPTIC REFLECTIVE ELEMENT ASSEMBLY; and/or PCTApplication No. PCT/US2004/015424, filed May 18, 2004 by Donnelly Corp.et al. for MIRROR ASSEMBLY FOR VEHICLE; and/or U.S. patent applicationSer. No. 11/226,628, filed Sep. 14, 2005 (Attorney Docket DON01 P-1236);Ser. No. 11/021,065, filed Dec. 23, 2004, now U.S. Pat. No. 7,255,451;Ser. No. 10/528,269, filed Mar. 17, 2005, now U.S. Pat. No. 7,274,501;Ser. No. 10/533,762, filed May 4, 2005, now U.S. Pat. No. 7,184,190;and/or Ser. No. 11/021,065, filed Dec. 23, 2004, now U.S. Pat. No.7,255,451; and/or U.S. provisional applications Ser. No. 60/692,113,filed Jun. 20, 2005; Ser. No. 60/677,990, filed May 5, 2005; Ser. No.60/653,787, filed Feb. 17, 2005; Ser. No. 60/642,227, filed Jan. 7,2005; Ser. No. 60/638,250, filed Dec. 21, 2004; Ser. No. 60/624,091,filed Nov. 1, 2004; and Ser. No. 60/609,642, filed Sep. 14, 2004, whichare hereby incorporated herein by reference in their entireties.

As can be seen with reference to FIG. 4, the indicia reflector may beestablished over the reflective layer 20 at the front surface 14 a ofthe rear substrate 14 so that the rear substrate with the indiciareflector established thereon may be readily assembled with the frontsubstrate, electro-optic medium and seal in a suitable manner.Optionally, and as shown in FIG. 5, the indicia metallic reflector 24′may be applied to or established at a portion or region of the frontsurface 14 a of the rear substrate 14, and the metallic conductive layer20′ may be disposed or established over substantially the rest of thefront surface 14 a and over the indicia metallic reflector 24′, so thatthe indicia metallic reflector 24′ is behind the reflective layer 20 andbetween at least one layer 20 and the rear substrate. For example, theindicia layer 24′ may comprise a layer of chromium (such as about 2000angstroms thick), and the reflective coating may comprise a layer ofsilver (such as about 600 angstroms thick). The presence of the thickerlayer of chromium underneath the thin layer of silver provides a subtleviewable indicia layer at the reflective element, without adverselyeffecting the functionality of the reflective element. Optionally,materials for the layer may be selected to provide a difference in thereflectivity and/or color of the reflective coating or layer and theindicia layer to provide a discernible contrast so that the indicia isdiscernible by a person viewing the reflective element, yet stillprovides reflectivity at the indicia area so as to not unduly affect thefunctionality of the reflective element. Optionally, the indicia layeror reflector may be disposed or established at either side of a fourthsurface reflective coating at the rear surface of the rear substrate ina similar manner to provide the desired discernibility of the indicia atthe reflective element, without affecting the scope of the presentinvention.

The indicia reflector or layer may be established via any suitablemeans. For example, the indicia reflector may be disposed, such as bysputter coating or the like, at a masked area of the substrate surfaceto dispose the material at the desired location. Optionally, the indicialayer may be coated or screened onto the substrate surface or onto thereflective coating, such as by a screen/coat/strip process (where aresist pre-deposition is screened or printed onto the substrate, and theindicia layer (such as chromium or the like) is coated onto thesubstrate and the resist post deposition of the indicia layer materialis washed away, whereby the indicia layer material remains at thescreened or printed areas). Other means for applying or establishing orforming the indicia layer onto the substrate surface (or onto areflective coating on the substrate surface) may be implemented withoutaffecting the scope of the present invention.

Optionally, a light source or indicator may be positioned behind theindicia layer, such as at a circuit board within the mirror, toilluminate or backlight the indicia layer to further enhance viewing ofthe indicia, particularly in low lighting conditions, such as atnighttime. Optionally, the illumination source or light source behindthe indicia may be selected to match the color that may be typicallyassociated with the selected logo (such as discussed below), such as agreen or red or blue indicator or light emitting diode or the like forthe school color or the like. Other forms of customized logos or indiciaor the like and associated illumination sources and the like may beestablished at the reflective element, without affecting the scope ofthe present invention.

Although shown and described as an exterior rearview mirror assembly,the reflective element of the present invention may be suitable for usewith an interior rearview mirror assembly, where the reflective elementand a housing of the mirror are pivotally or adjustably mounted to aninterior portion of a vehicle, such as via a double ball mounting orbracket assembly or the like.

Optionally, the indicia layer may provide a graphic depiction of adesired image, such as a logo of the vehicle manufacturer or otherdesired image. For example, the indicia may be established or otherwiseformed to provide the letters “FORD” or may be established or otherwiseformed in a pattern similar to the design or designs indicative of themanufacturer, such as the Chevrolet “bowtie” or the like. Optionally,other designs or patterns or text or logos or indicia or the like may beprovided at the reflective element to provide a desired image or logo.For example, the indicia layer may be formed to be indicative of othervehicle manufacturers or entities or sponsors or indicia or trademarksor emblems or signature items, or representations of a certain politicalviews, religious beliefs, tribal affiliations, community ties,collegiate affiliations, allegiances and/or advocacy (such as, forexample, a “peace” sign or other symbol or text or the like) or otherviews, affiliations, beliefs, etc., or other custom ports or icons maybe formed elsewhere on the reflective element to convey otherinformation or logos or the like, without affecting the scope of thepresent invention (and such as described in U.S. patent application Ser.No. 11/021,065, filed Dec. 23, 2004, now U.S. Pat. No. 7,255,451, and/orPCT Application No. PCT/US2004/015424, filed May 18, 2004 by DonnellyCorp. et al. for MIRROR ASSEMBLY FOR VEHICLE, which are herebyincorporated herein by reference in their entireties).

The desired image or logo may be indicative of the vehicle manufacturer,or may be selected by the user or vehicle owner to provide a customizedinterior or exterior rearview mirror assembly, such as described abovewith respect to the different logos or colors, without affecting thescope of the present invention. For example, a person may select thelogo or mascot of their alma mater to be established at a desiredlocation at the reflective element to customize the mirror assembly forthat particular person or owner. The customized reflective element mayprovide the desired logo or indicia or the like, without undulyaffecting the functionality of the reflective element.

Optionally, and as shown in FIGS. 1 and 2, the reflective element 10 mayinclude a perimeter metallic band 26, such as the types described in PCTApplication No. PCT/US03/29776, filed Sep. 19, 2003 by Donnelly Corp. etal. for ELECTROCHROMIC MIRROR ASSEMBLY; and/or PCT Application No.PCT/US03/35381, filed Nov. 5, 2003 by Donnelly Corp. et al. forELECTRO-OPTIC REFLECTIVE ELEMENT ASSEMBLY; and/or U.S. patentapplication Ser. No. 11/021,065, filed Dec. 23, 2004, now U.S. Pat. No.7,255,451; Ser. No. 10/528,269, filed Mar. 17, 2005, now U.S. Pat. No.7,274,501; Ser. No. 10/533,762, filed May 4, 2005, now U.S. Pat. No.7,184,190; Ser. No. 11/226,628, filed Sep. 14, 2005 (Attorney DocketDON01 P-1236); and/or Ser. No. 11/021,065, filed Dec. 23, 2004, now U.S.Pat. No. 7,255,451; and/or U.S. provisional applications Ser. No.60/692,113, filed Jun. 20, 2005; Ser. No. 60/677,990, filed May 5, 2005;Ser. No. 60/653,787, filed Feb. 17, 2005; Ser. No. 60/642,227, filedJan. 7, 2005; Ser. No. 60/638,250, filed Dec. 21, 2004; Ser. No.60/624,091, filed Nov. 1, 2004, and Ser. No. 60/609,642, filed Sep. 14,2004, which are hereby incorporated herein by reference in theirentireties. The perimeter band metallic material may be selected toprovide a desired band color, such as due to interference effects ormaterial colors and/or reflectances and/or refractive indices.Optionally, the material for the perimeter band may be selected so thatthe appearance or color of the perimeter band may substantially match orcontrast the appearance or color of the indicia layer or reflector,depending on the desired appearance of the reflective element. Forexample, a combination or stack of oxides comprising materials havingdifferent high and low refractive indices may be stacked upon oneanother to provide alternating refractive indices to spectrally tune themetallic band and/or the indicia reflector or layer to the desiredcolors or tints or appearances (such as utilizing principles describedin PCT Application No. PCT/US03/29776, filed Sep. 19, 2003 by DonnellyCorp. et al. for ELECTROCHROMIC MIRROR ASSEMBLY, and/or Ser. No.10/528,269, filed Mar. 17, 2005, now U.S. Pat. No. 7,274,501, which arehereby incorporated herein by reference in their entireties).

Optionally, and with reference to FIG. 6, a reflective element assemblyor cell 110 for a rearview mirror assembly, such as for an interior orexterior rearview mirror assembly for a vehicle, includes a frontsubstrate 112 and a rear substrate 114 spaced from front reflectiveelement substrate 112, with an electrolyte or a cured monomercomposition or electrochromic medium 116 sandwiched therebetween. Thefront substrate 112 has a transparent conductive coating or layer 118disposed on its rear surface 112 a (typically referred to as the secondsurface of the reflective element assembly) and the rear substrate 114has a metallic conductive coating or layer 120 disposed on its frontsurface 114 a (typically referred to as the third surface of thereflective element assembly), such as described above. As can be seen inFIG. 6, the indicia 126 is locally deposited or established or disposedat the second surface of the front substrate at the desired locationand/or pattern (and with the ITO coating adjacent to or over theindicia), while the metallic conductive coating 120 is deposited orestablished or disposed over substantially the entire third surface ofthe rear substrate so as to be behind and surrounding the indicia asviewed by the driver when the mirror assembly is installed at thevehicle. An epoxy seal material 122 or the like, is applied between thesubstrates to define the cavity for the electrochromic medium and toadhere the substrates together. Reflective element assembly 110 includesa reflective perimeter or border band 126 and a reflectant indicia layer124 disposed or otherwise formed or established at the rear or secondsurface 112 a of the front substrate 112.

Indicia layer 124 may be established during the same coating process asthe perimeter band 126 and may be established on the rear surface of thesubstrate, so that the transparent conductive layer 118 is disposed orestablished onto the perimeter band 126 and indicia layer 124 and overthe rear surface 112 a of front substrate 112. For example, the rearsurface of the front substrate may be masked to define the perimeterborder and the desired indicia or form. The mask may be etched or cut orpunched to provide the desired indicia or logo or the like (which mayappear in a reverse image manner when the mask is placed on the rearsurface of the front substrate). The etched mask thus may be placed ator on the rear surface of the front substrate and the desired reflectivematerial (such as described below) may be disposed onto the rear surfaceof the substrate in the unmasked or uncovered areas. The reflectiveindicia may be formed so as to be located at the electrochromic portionof the mirror (radially inward from the seal and perimeter or borderband), so as to be readily viewable by the driver of the vehicle and soas to be visibly effected by the darkening of the electrochromic mediumand the corresponding dimming of the electrochromic mirror, as discussedbelow.

Preferably, metallic conductive coating 120 comprises a substantiallyhighly reflective material with a high degree of reflectivity of lightincident thereon. For example, the third surface coating 120 maycomprise aluminum or silver or their alloys (or other similar orsuitable metallic compositions and the like), and may provide greaterthan about 80 percent reflectivity of light incident thereon (asmeasured using SAE 3964 a) and more preferably greater than about 90percent reflectivity of light incident thereon. Preferably, thereflective indicia 124 (and the reflective perimeter band 126) comprisesa lower or reduced reflectivity of light incident thereon than thatprovided by the third surface reflective coating. For example, thereflective indicia 124 may comprise chromium or titanium or nickel ormolybdenum or ruthenium or their alloys or other similar or suitablemetal (such as a stainless steel or a nickel based alloy, such asHastelloy C), and may provide about 65 percent reflectivity of lightincident thereon, and more preferably less than about 55 percentreflectivity of light incident thereon (such as between about 35 percentreflectivity to about 65 percent reflectivity of light incidentthereon).

Indicia layer 124 may also comprise a specularly reflective layer,preferably such as a mirror-reflective thin film of chromium, ruthenium,silver, silver alloy, aluminum, aluminum alloy or other metal or metalalloy. Thus, and preferably, the indicia layer material comprises ametallic material such that is locally provides a mirror-like reflectionat the second surface of the front substrate that is subtly discernibleagainst the third surface mirror reflector at the third surface of therear substrate of the electrochromic reflective element. Such a specularor mirror-like reflective material may be attained from a sputtered orvacuum deposited metallic thin film coated onto the substrate. Theindicia coating or coatings or layer(s) may be disposed onto thesubstrate surface at the desired location and pattern with thetransparent electrically conductive coating of the second surface of thefront substrate (such as ITO or other transparent electricallyconductive coatings, such as doped tin oxide or doped zinc oxide such asZnO:Al or the like) deposited over the glass surface and over theindicia material (so that the reflection off the indicia layer(s) isunaffected by the ITO disposed therebehind and thus more metallic or“silvery” in hue and is substantially spectrally neutral rather thanbeing spectrally reflecting/tinted), or the ITO coating may be depositedonto the second-surface surface of the front substrate with the indiciacoating material disposed onto the ITO-coated surface at the desiredlocation and pattern (so that the reflection off the indicia layer(s)is/are seen through the ITO and so an interference spectral character tosuch reflectivity may be imparted), depending on the particularapplication and desired appearance/effect of the mirror reflectiveelement assembly.

Although shown as a mirror reflective element having the front substrate112 larger than the rear substrate, such as for a frameless mirrorreflective element for an exterior rearview mirror assembly, the minorreflective element with indicia may comprise other types of reflectiveelements, such as a flush reflective element for an interior or exteriorrearview mirror assembly or an offset construction such as is known inthe electro-optic minor art, without affecting the scope of the presentinvention. For example, and as shown in FIG. 6A, a reflective element110′ (preferably an exterior vehicular mirror element) may have a frontsubstrate 112′ that is substantially flush with the rear substrate 114′,with a reflective indicia or logo 124′ (and optionally and preferably aperimeter border band 126′ as well) established at the second surface112 a′ of front substrate 112′. The front substrate 112′ is spaced fromthe rear substrate 114′ with an electrochromic medium 116′ disposedtherebetween and sealed by a perimeter seal 122′. The logo or indicia124′ (locally established inboard of the perimeter edge or border of thefront substrate on its second surface) and border band 126′ (at andsubstantially circumscribing the second-surface perimeter edge or borderregion of the front substrate) preferably comprise the same metallicreflecting layer, such as sputtered chromium or the like or havedistinctly different reflectivity (such as chromium for indicia 124′ andruthenium for border band 126′), and are preferably established via thesame coating process as described above. Reflective element 110′includes a transparent conductive coating 118′ at the second surface 112a′ (such as disposed or established over the perimeter border band 126′and indicia 124′, such as described above), which may comprise an ITOcoating or a doped zinc oxide (such as ZnO:Al) coating (such as thetypes discussed below) or other suitable transparent conductive coatingor layer or material.

The third surface reflective coating or layers 120′ at the third surface114 a′ of rear substrate 114′ may comprise any suitable material ormaterials or layers to provide the desired reflectivity and/ortransreflectivity at the third surface of the mirror reflective element.For example, the third surface coatings 120′ may comprise a layer ofchromium 120 a′ at the third surface 114 a′ of rear substrate 114′, witha layer of ruthenium 120 b′ disposed over the layer of chromium 120 a′.In such an application, the indicia 124′ may comprise chromium and thefront-most layer 120 b′ of third surface reflector 120′ may compriseruthenium (that typically is about 5-20 percent or so more reflectingthan chromium, depending on the deposition conditions employed), or bothmay be similar or identical materials (e.g. chromium or ruthenium). Evenwith the same materials, the indicia is still discernible due to acontrast between the indicia 124′ at the second surface and the coatingsor layers 120′ at the third surface (due to the optical properties suchas refractive index and spectral absorption of the electro-optic ECmedium disposed between the second and third surfaces). In theillustrated embodiment, the ITO layer 118′ is disposed over the indicia124′, but optionally the ITO layer may be disposed at the second surfacewith the indicia disposed over the ITO at the desired location orpattern. If the ITO is established at the second surface before theindicia, the indicia may be colored or tinted due to the opticalinterference effect or coloring caused by the ITO (when the ITO isbetween the substrate and the indicia and thus the indicia is viewedthrough the ITO coating by a person viewing the mirror reflectiveelement). Such an arrangement may provide a gold-tinted or blue-tintedor other color tint to the indicia, dependent principally on thethickness of the ITO (or other transparent conductive material) used,which may be preferred depending on the particular application of themirror assembly and desired effect or appearance of the mirror assembly.Optionally, indicia layer(s) 124′ may be formed of a metallic metalcoating (such as of gold or a gold alloy) that is itself spectrallyselective in reflectivity so as to be tinted in reflection.

Optionally, and as shown in FIG. 6B, a mirror reflective element 110″(preferably an exterior vehicular mirror element) may be substantiallysimilar to mirror reflective element 110′ as described above, and mayinclude a third surface coating or layers 120″ at a rear surface 114 a″of the rear substrate 114″ that comprises a layer of chromium 120 a″disposed at the third surface of the rear substrate, with a layer ofsilver 120 b″ disposed over the layer of chromium 120 a″ and a layer ofaluminum zinc oxide 120 c″ (ZnO:Al) disposed over the layer of silver120 b″. The third surface reflector thus comprises a different materialand specular reflectivity as compared to the chromium indicia 124′,whereby the indicia may be more readily discernible by a person viewingthe reflective element when the reflective element is in its “day” statedue to the contrast between the much more highly reflecting thirdsurface main mirror reflector (typically a silver or silver-alloy metalcoating that has a specular first-surface reflectivity, as measured inaccordance with SAE J964a, that is at least about 80% R and often atleast about 90% R) and the less highly reflecting second-surfaceindicia/logo reflecting coating or layer (for example, an evaporatedchromium coating that has a reflectivity of about 45-55% R or asputtered chromium coating that has a reflectivity of about 55-65% R).Other stacks or layers of metallic conductive reflective ortransflective coatings or layers may be implemented to achieve thedesired reflectivity and transmissivity at the third surface of thereflective element, while providing a desired degree of discernibilityof the indicia, while remaining within the spirit and scope of thepresent invention. The indicia material and third surface reflectormaterial and arrangement of the indicia and ITO coatings may be selectedto achieve the desired color and reflectivity differential of theindicia relative to the third surface reflector, depending on theparticular application and desired effect of the mirror assembly.

Because the reflective indicia that is locally established in a patternon the second surface of the front substrate is desirably lessreflective than the third surface reflective coating on the rearsubstrate (when the mirror is in its “day” or undimmed state or highreflectance state) or, less desirably, vice versa, and is surrounded byand backdropped by the third surface reflective coating (whichpreferably provides a higher reflectivity background to the indicia),the indicia is subtly (such as via the differences in reflectivities ofthe materials used) discernible by a person viewing the reflectiveelement when the EC medium is unpowered and is in its high reflectancestate. The viewability and discernibility of the indicia may be subtlewhen the reflective surface of the rear substrate is at its highlyreflective state or when the electrochromic medium is not darkened.Thus, during the unpowered state of the electrochromic mirror, theindicia may be subtly viewable and discernible by a person viewing themirror assembly. However, when the electrochromic mirror is powered todarken the electrochromic medium and thus to dim the mirror (such as inresponse to a glare sensor or the like located at the mirror assembly orelsewhere in the vehicle), the reflectivity of light provided by thethird surface reflective coating is reduced (due to the darkening of theelectrochromic medium in front of the third surface reflective coating),so that the indicia becomes more visible or more discernible to a personviewing the mirror. In other words, the indicia may be enhanced and morereadily viewable and discernible as the mirror is darkened and thereflectivity of the third surface reflective coating is limited orreduced by the darkening of the electrochromic medium.

Optionally, the third surface metal reflector on the third surface ofthe rear substrate of the cell, the perimeter reflective border bandaround the edge border of the second surface of the front substrate, andthe indicia (also on the second surface but inward of the border band)may be reflective materials, and may comprise substantially the samemetallic or reflective material, so that all three have similar orclosely similar reflective properties, and may all have substantiallythe same optical properties, such as reflectivity level and refractiveindex/k-value. By so choosing, the optical contrast between the thirdsurface reflector coating and the second surface perimeter border issubstantially reduced and essentially eliminated such that the viewerbarely sees or notices the presence of the second surface border bandwhen the electrochromic cell is not powered (i.e. is undimmed and is inits bleached state), and the presence of the border reflective band isonly discernable when the electrochromic medium dims when the cell ispowered. Also, the presence of the indicia (such as an ANTI-GLAREindicia or AUTODIM indicia or the like) on the second surface is subtlynoticeable to a viewer because its optical properties substantiallymatch those of the third surface reflector coating (for example,chromium may be used for the indicia and ruthenium for the third surfacereflector for an exterior mirror element, or chromium may be used forthe indicia and silver or a silver-alloy may be used for the thirdsurface reflector for an interior mirror element), such that the viewersubtly sees or notices or discerns the presence of the second surfaceindicia when the electrochromic cell is not powered (i.e. is undimmedand in its bleached state), but the presence of the indicia on thesecond surface becomes appreciably discernable when the electrochromicmedium dims when the cell is powered, and in such circumstances providesa “surprise and delight” benefit to the consumer.

This is particularly advantageous when an AUTODIM or similar automaticdimming indication logo/indicia is used. When the likes of anelectrochromic automatic dimming interior mirror element dims inreflectivity at night when rear-approaching glaring headlights aredetected, the driver is often unaware of and thus unappreciative of theanti-glare benefits of this feature. In accordance with the presentinvention, the AUTODIM logo/indicia on the second surface of the frontsubstrate becomes plainly visible once the electro-optic EC medium ispowered at night when the mirror element is subject to and is beingilluminated by incident light from approaching headlights that aresufficiently intense to cause the automatic glare detection circuitry topower the electro-optic EC medium. And the more intense the glaredetected, the darker the electro-optic EC medium dims and the more thesecond-surface logo/indicia stands out, and so the continuously variablereflectivity feature of such automatic electrochromic mirror assembliesis conveyed to the driver. Note that, for example, the third surfacereflector coating and the second surface perimetal border reflector band(if present) and the second surface indicia may all three comprisechromium thin films or all three may comprise ruthenium thin films orall three may comprise rhodium thin films or all three may compriseHastelloy C-276 thin films or all three may comprise molybdenum thinfilms or all three may comprise aluminum (or aluminum alloy) thin filmsor all three may comprise aluminum/palladium alloy thin films or allthree may comprise silver (or silver alloy) thin films, or all three maycomprise sub-sets of these or other suitable coatings or films.

Thus, the indicia may optionally be selected to provide information thatmay be relevant to the driver of the vehicle during night driving whenthe EC medium dims or darkens in response to detected incident glaringconditions. For example, the logo/indicia may provide a notice orindication to the driver that the electrochromic mirror assembly ispowered and thus in an active mode or darkened or dimmed mode, in orderto provide a visual reinforcement or communication to the driver thatthe mirror assembly is working in the desired and designed manner, andis delivering glare protection. Such an information display logo orindication is thus desirable, since customers may not otherwise readilyrecognize that the electrochromic mirror is properly dimming, and thusmay not otherwise fully appreciate the benefits provided by theautomatic mirror dimming feature. For example, the indicia can read“AUTODIM” or “ANTI-GLARE” or “BC” or “NIGHT” or may be an icon, such asa representation of a headlamp with a cross or “X” superimposed thereon,indicating that the glare or reflection of the light from the headlampsis being reduced or dimmed by the mirror. Optionally, the logo/indiciamay convey other information, such as an automaker brand orpersonalization information, to the driver that stands out when the ECmedium dims.

The indicia material of the present invention thus may provide areflective logo that is faintly visible/discernible to the driver whenthe EC mirror is in its “day” state (where the EC medium is not darkenedor colored), but becomes plainly or substantially visible/discerniblewhen the EC mirror dims to its “night” state (when the EC medium isdarkened or colored to reduce glare at the reflective element). Forexample, the reflective logo may be locally coated or established at thesecond surface of the front substrate and may have a reflectivity ofabout 55 percent of light incident thereon, while the main or primarymirror reflector established at the third surface of the rear substratemay have a reflectivity of about 70 percent of light incident thereon.Thus, in the “day” state, the driver can discern the lower reflectivityof the logo against the distinctly higher or brighter reflectivity ofthe main minor reflector behind the logo; whereby the logo is subtly butdistinctly visible/discernible at the mirror reflective element whilethe minor reflectivity of light incident thereon is sustained across theviewing surface, even at the location where the logo is disposed orestablished. Because a person's eyes typically can discern a differencein reflectivity of about 5 percent, and can more readily discern adifference in reflectivity of about 10 percent or more, the differencein reflectivity between the logo and the third surface mirror reflectoris readily discernible by the driver of the vehicle when the mirror isin its “day” state.

When the mirror changes to its “night” or antiglare state, thereflectivity of the primary mirror reflector is substantially reduced(due to the darkening or coloring of the EC medium), while thereflectivity of the logo (established at the second surface and thus infront of the EC medium) is substantially unaffected by the activation ofthe EC mirror. Thus, when the EC mirror dims, the logo “stands-out” orbecomes plainly or substantially visible or discernible at thereflective element. The indicia or logo may be selected to convey thedesired message or information or display to the viewer. For example,the logo may comprise the term “AUTODIM” or “ANTI-GLARE” or the like toindicate to the driver that the EC mirror has such a feature.Optionally, the logo may comprise a personalized logo, such as a sportslogo or college logo or the like (which may be selected by the user orowner of the vehicle) or a vehicle logo, such as “FORD” or “GM” or thelike, depending on the particular application and desired display orappearance of the mirror assembly.

The indicia material and the third surface reflector material maycomprise similar materials or may comprise different reflectivematerials, depending on the desired appearance and effect of thereflective element. For example, the indicia material may be selected asa gold or bronze colored or tinted material (such as a gold or goldalloy or the like) to provide a desired spectral appearance. Such acolored or tinted indicia material may be more readily discernible atthe reflective element since it is backdropped and surrounded by thespecularly reflective mirror reflector at the third surface. The thirdsurface mirror reflector may comprise any suitable reflective ortransflective material or materials, such as an ISI (ITO-silver-ITO)stack of layers or layers including other metallic materials, such assilver alloys and the like, such as the other materials discussedherein), and provides a specularly reflective (and optionallytransreflective) mirror reflector behind and around the indicia asviewed by a driver of the vehicle.

Note that the degree of subtly that the logo/indicia is discernible tothe driver when the electrochromic (EC) medium is not powered (i.e., theEC mirror element is in its high or “day” reflectance state) can bedetermined by the choices made for the logo/indicia metallic reflectinglayer and those of the third surface reflector (or fourth surfacereflector) metallic main mirror reflecting layer. For example, achromium or similar lower reflecting (typically with a first-surfacereflectivity in the about 45% R to about 65% R range) metal coatingchoice for the logo/indicia will be more discernible if the main mirrorreflector (that preferably is on the third surface rather than on thefourth surface) is a high reflecting reflector [such as a silver mirrorcoating (or a silver alloy) with a first-surface reflectivity of atleast about 80% R (and often greater than about 90% R)] than it would beif the main mirror reflector is a medium reflecting reflector [such as aruthenium mirror coating (or a ruthenium alloy or a platinum orpalladium metal or alloy) with a first-surface reflectivity in the about65% R to about 75% R range, typically]. Also, should the metalliclogo/indicia overcoat the transparent conductor coating (such as ITO orAZO) of the second surface (and thus be located behind the transparentconductor coating when the mirror reflective element is viewed by aperson at the vehicle), the metallic logo/indicia may be less subtlydiscernible than if the metallic logo/indicia undercoats the transparentconductor coating (because the metallic logo/indicia is subject tooptical interference effects and has a spectrally selective reflectivityso as to be color tinted in reflectance when the metallic logo/indiciaovercoats and is thus located behind the transparent conductor coating).

Particularly for an exterior mirror, a user typically cannot discernthat the EC function is working, since there is no feedback to the userwhen the EC function is operating to dim or darken the mirrorreflection. The increased viewability of the indicia when the EC mediumis darkened provides a visual prompt to the user to reinforce to theconsumer the value of the feature, particularly for exterior mirrorapplications, such that the consumer may recognize the value andfunctionality of the feature and may increase the use the EC feature,thereby enhancing safety. Although it is known to provide LEDs or thelike to interior mirror assemblies, the indicia of the present inventionprovides a similar function, but with reduced costs and complexity ofthe mirror assembly, since no additional electronic LED or the like isneeded to convey the indication that the EC minor is powered.

Although shown and described as having a third surface reflectivecoating, the reflective element may have a fourth surface reflectivecoating, without affecting the scope of the present invention.Optionally, and as shown in FIG. 6, the third surface reflectivemetallic coating may be disposed over the perimeter edge or edges of therear substrate so as to provide a wraparound portion at the perimeteredge or edges for electrical connection of electrical connectors at thefourth surface 114 a of the reflective element assembly 110 to theconductive coatings 118, 120, such as by utilizing aspects described inU.S. patent application Ser. No. 11/226,628, filed Sep. 14, 2005(Attorney Docket DON01 P-1236); and/or Ser. No. 11/021,065, filed Dec.23, 2004, now U.S. Pat. No. 7,255,451, which are hereby incorporatedherein by reference in their entireties.

Also, although shown and described with the perimeter band and indiciabeing formed directly on the rear surface of the front (first) substrateand with the transparent conductive coating disposed over the perimeterband and indicia, the transparent conductive coating may first bedisposed over the rear surface of the front substrate with the perimeterband and indicia then being disposed onto the transparent conductivecoating, without affecting the scope of the present invention. Such anarrangement may be desired if a color or tint of the perimeter band andindicia, such as due to the interference effect of the transparentconductive coating between the perimeter band/indicia and the substratesurface, such as described above and by utilizing aspects described inU.S. patent application Ser. No. 11/226,628, filed Sep. 14, 2005(Attorney Docket DON01 P-1236); and/or Ser. No. 11/021,065, filed Dec.23, 2004, now U.S. Pat. No. 7,255,451; and/or U.S. provisionalapplications Ser. No. 60/692,113, filed Jun. 20, 2005; Ser. No.60/677,990, filed May 5, 2005; Ser. No. 60/653,787, filed Feb. 17, 2005;Ser. No. 60/642,227, filed Jan. 7, 2005; Ser. No. 60/638,250, filed Dec.21, 2004; Ser. No. 60/624,091, filed Nov. 1, 2004, and Ser. No.60/609,642, filed Sep. 14, 2004, which are hereby incorporated herein byreference in their entireties.

The indicia and the perimeter band or coating may be established ontothe substrate surface, such as onto the rear surface of the frontsubstrate via the same coating operation and with the same material. Theindicia thus may be established without additional coating processes,since the indicia is established by using the same mask and coating thatnormally would be utilized for establishing the perimeter coating orband. The indicia is thus established at the substrate surface in ahighly economical manner. For example, a substrate may be provided and amask (with an outer portion defining the perimeter band and with theindicia formed or cut through the mask) may be placed on the substratesurface (such as the rear surface of the front substrate). The desiredmetallic layer material may be disposed at the substrate surface so asto be established at the unmasked perimeter band and indicia regions viaa single deposition process or the like. The perimeter band and theindicia thus may be readily established in an economical manner withoutmultiple steps or processes and with the same material so that theindicia may substantially match the perimeter band in appearance orcolor or tint or discernibility.

Although shown and described as an electro-optic or electrochromicreflective element assembly or cell, the reflective element may comprisea single substrate with a reflective coating at its rear surface,without affecting the scope of the present invention. The indicia layermay be disposed or established at the rear of the reflective coating soas to be discernible through the substrate and reflective coating, ormay be disposed or established between the reflective coating and therear surface of the substrate, such as in a similar manner as describedabove. The mirror assembly may comprise a prismatic mirror assembly orother mirror having a single substrate reflective element, such as amirror assembly utilizing aspects described in U.S. Pat. Nos. 6,318,870;6,598,980; 5,327,288; 4,948,242; 4,826,289; 4,436,371; and 4,435,042;and PCT Application No. PCT/US04/015424, filed May 18, 2004 by DonnellyCorporation et al. for MIRROR ASSEMBLY FOR VEHICLE; and U.S. patentapplication Ser. No. 10/933,842, filed Sep. 3, 2004, now U.S. Pat. No.7,249,860, which are hereby incorporated herein by reference in theirentireties. Optionally, the prismatic reflective element may comprise aconventional prismatic or flat reflective element or prism, or maycomprise a prismatic or flat reflective element of the types describedin PCT Application No. PCT/US03/29776, filed Sep. 19, 2003 by DonnellyCorp. et al. for MIRROR REFLECTIVE ELEMENT ASSEMBLY; U.S. patentapplication Ser. No. 10/528,269, filed Mar. 17, 2005, now U.S. Pat. No.7,274,501; Ser. No. 10/709,434, filed May 5, 2004, now U.S. Pat. No.7,420,756; Ser. No. 10/933,842, filed Sep. 3, 2004, now U.S. Pat. No.7,249,860; Ser. No. 11/021,065, filed Dec. 23, 2004, now U.S. Pat. No.7,255,451; and/or Ser. No. 10/993,302, filed Nov. 19, 2004, now U.S.Pat. No. 7,338,177, and/or PCT Application No. PCT/US2004/015424, filedMay 18, 2004 by Donnelly Corp. et al. for MIRROR ASSEMBLY FOR VEHICLE,which are all hereby incorporated herein by reference in theirentireties, without affecting the scope of the present invention. Avariety of mirror accessories and constructions are known in the art,such as those disclosed in U.S. Pat. Nos. 5,555,136; 5,582,383;5,680,263; 5,984,482; 6,227,675; 6,229,319; and 6,315,421 (the entiredisclosures of which are hereby incorporated herein by reference intheir entireties), that can benefit from the present invention. Thesubtle contrast indicia of the present invention may be established onany of a first, second, third or fourth surface of a laminate-typeelectro optic mirror cell or on any of a first or second surface of asingle-substrate mirror element.

Optionally, a mirror reflective element may include a display elementthat emits or projects illumination through a pattern or indicia formedor established at the reflective element. For example, and withreference to FIG. 7, a mirror reflective element 210 for a rearviewmirror assembly, such as for an interior or exterior rearview mirrorassembly for a vehicle, includes a front substrate 212 and a rearsubstrate 214 spaced from front reflective element substrate 212, withan electrolyte or a cured monomer composition or electrochromic medium216 sandwiched therebetween. The front substrate 212 has a transparentconductive coating or layer 218 (such as an ITO layer, such as a ½ waveITO layer or a doped tin oxide layer or a doped zinc oxide layer or alight transmissive metal oxide/metal/metal oxide stack such asITO/Ag/ITO or ZnAlO/Ag/ZnAlO or ZnAlO/Al/ZnAlO or ITO/Ag/ZnAlO or thelike) disposed on its rear surface 212 a (typically referred to as thesecond surface of the reflective element assembly) and the rearsubstrate 214 has a metallic conductive coating or layer 220 disposed onand substantially over its front surface 214 a (typically referred to asthe third surface of the reflective element assembly), such as describedabove. An epoxy seal material 222 or the like, is applied between thesubstrates to define the cavity for the electrochromic medium and toadhere the substrates together. In the illustrated embodiment,reflective element assembly 210 includes a reflective perimeter orborder band 226 disposed or otherwise formed or established at the rearor second surface 212 a of the front substrate 212, such as describedabove.

Reflective element 210 includes a display element 230 located rearwardof the reflective element and directed at a pattern or indicia 232formed or established at the rear surface 214 b of rear substrate 214(commonly referred to as the fourth surface of the reflective element).The pattern 232 may comprise the likes of a pattern of stars or dots, apattern of bars or bar segments, portions of which may be connected orunconnected to each other, or other patterns or indicia or the like. Thepattern or indicia 232 may comprise any suitable material (such aschromium, molybdenum or tungsten or the like) and may provide adecorative or light management effect that is viewable and discernibleby the driver of the vehicle (or other person viewing the minor) whenthe display element 230 (such as a light source, such as a lightemitting diode (LED) or the like) is activated. For example, the pattern232 may be formed to indicate that the turn signal of the subjectvehicle is activated, such as for exterior mirror applications forindicating to a driver of an adjacent vehicle that the turn signal ofthe subject vehicle is activated. The indicia or pattern or structureestablished at the fourth surface of the reflective element thus maybreak up or direct light from the display element and/or may obscure orhide the presence of the display element from direct view by a personviewing the reflective element, so as to provide a desired appearance ordirection of the light passing through the reflective element forviewing by the driver of the vehicle or other person within or outsideof the vehicle. Optionally, the pattern may be thin film coating or athick film coating, such as a printed pattern or painted pattern, suchas a paint or ink or lacquer, or such as an adhesively applied or“stick-on” element or appliqué or the like. For example, the pattern orindicia may be printed or painted or coated or otherwise applied ordisposed at a portion of the rear surface of the reflective element, ormay be coated or applied or formed or otherwise established on a Mylarshape (or other substrate or the like) that may be adhered to the rearsurface of the reflective element, thereby avoiding coating the entirerear surface or substantially the entire rear surface of the reflectiveelement.

The third surface conductive coating 220 may comprise a transflectivecoating or layer or other suitable third surface reflective andconductive coatings. In the illustrated embodiment, the third surfaceconductive coating 220 comprises a layer of a transparent conductivematerial 220 a (such as ITO or the like) over substantially the entirefront surface 214 a of the rear substrate 214, and a reflective coatingor layer 220 b (or multiple coatings or layers), such as a layer ofchromium/rhodium or chromium/ruthenium or molybdenum/chromium or anITO/silver/ITO stack of layers or the like. A window or aperture 234 isformed or established in the reflective coating or coatings 220 b (suchas by laser ablating or etching the reflective coating 220 b to removethe coating 220 b at the window area [or by masking the metallictransflective coating 220 b while it is being deposited onto thetransparent conductive layer 220 a], while maintaining the transparentconductive coating 220 a at the window area).

As shown in FIG. 7, the reflective element 210 may include a fourthsurface conductor 236 a and wrap-around coating 236 b that wraps aroundand over a perimeter edge 214 c of rear substrate 214 and over a thirdsurface conductive wraparound coating 220 c at the perimeter edge 214 c,in order to provide electrical conductivity between the fourth surfaceconductor 236 a and the third surface conductive and reflective coating220 b. Preferably, the indicia or pattern 232 is formed or establishedduring the same coating process that establishes the fourth surfaceconductor 236 a and wrap-around coating 236 b and thus may comprise thesame material as the fourth surface conductor 236 a and wrap-aroundcoating 236 b (such as chromium or molybdenum or tungsten or Hastelloyor ruthenium or rhodium or other suitable conductive material).Alternately, the pattern or indicia 232 may comprise a differentmaterial and may be established via a different coating or forming orestablishing process.

For example, and with reference to FIG. 8, the reflective element 210′may include a transflective coating or layer or appliqué 232′established at the fourth surface 214 b′ of the reflective element 214′and at the display element 230 and generally opposite the window area234 at the third surface reflective coating 220 b. The transflectivecoating 232′ thus may provide a reflective appearance at the window area234, while allowing light from display element 230 to pass through thetransflective coating 232′ and through the reflective element 210′ forviewing by a person viewing the mirror reflective element assembly. Thetransparent conductive coating 220 a may be disposed over substantiallythe entire front surface 214 a′ of rear substrate 214′, while the thirdsurface reflective coating or reflector 220 b may have an aperture 234established therein, such as described above.

Optionally, and with reference to FIG. 9, the reflective element 210″may include a display module 229 that may be attached or adhered orestablished at the rear surface 214 b″ of rear substrate 214″ andgenerally opposite the window area 234 formed in the third surfacereflective coating 220 b (that is disposed on the transparent conductivelayer 220 a [such as a layer or coating of ITO or the like, such as alayer of 80 ohms/sq. ITO or the like] at the front surface 214 a″ ofrear substrate 214″). The display module 229 includes a housing 229 a, alight source or display element 230″ (such as a light emitting diode orother suitable light source) and a transflective window element 232″.The housing 229 a may include electrical connectors 229 b forelectrically connecting the display module 229 to a power source orcircuitry of the mirror assembly. Preferably, display module 229 may beattached to the rear surface 214 b″ of rear substrate 214″ via anoptical index matching adhesive 229 c, such as an optical epoxy oroptical acrylic (such as utilizing aspects of the reflective elementdescribed in U.S. patent application Ser. No. 10/993,302, filed Nov. 19,2004, now U.S. Pat. No. 7,338,177, which is hereby incorporated hereinby reference in its entirety. The housing 229 a may mount or receive thedisplay element 230″ such that the light is emitted at an angle throughthe transflective window and the reflective element (such as, forexample, for a blind spot system indicator whose light output isdirected into the vehicle cabin so as to be seen by the driver of thehost vehicle) to enhance viewability and discernibility of the display(or to reduce the viewability or discernibility of the display, such asby directing the light output away from the cabin of the vehicle so thatthe light output is not readily discernible by the driver of the hostvehicle) to a person viewing the reflective element at an angle. Thehousing 229 a may have a polished or reflective or otherwise shaped orformed inner surface to enhance directing of the light toward andthrough the reflective element when the display module 229 is attachedto the fourth surface of the reflective element. Optionally, the displaymodule may include a pattern or indicia formed on a window element,which may or may not comprise a transflective window element, in orderto provide the desired pattern or appearance of the display.

Reflective elements 210′ and 210″ of FIGS. 8 and 9 may be otherwisesubstantially similar to the reflective element 210 and other reflectiveelements described above, such that a detailed discussion of thereflective elements will not be repeated herein. The common or similarelements of the reflective elements are shown in FIGS. 8 and 9 with thesame reference numbers as used in FIG. 7 with respect to reflectiveelement 210.

Optionally, and with reference to FIGS. 10A-C, a mirror reflectiveelement 250, such as an exterior mirror reflective element, includes aglass substrate 252, a transflective mirror reflector 254 and a displayelement, such as a turn signal indicator 256, at the rear of thesubstrate 252 and behind the transflective mirror reflector 254. Themirror reflective element may comprise a single glass substrate (such asglass substrate 252 shown in FIG. 10A), or may comprise an electro-opticreflective element assembly or cell, such as an electrochromicreflective element assembly or cell (such as electro-optic reflectiveelement assembly 250′ of FIG. 10D, discussed below, which includes afront substrate 252′ and a rear substrate 253′ with an electro-opticmedium 255′ disposed therebetween). In the illustrated embodiment, thetransflective mirror reflector 254 is disposed at the rear surface ofthe substrate 252. However, the transflective mirror reflector may bedisposed at the front surface of the substrate, without affecting thescope of the present invention. Turn signal indicator 256 is disposed atthe rear of the reflective element substrate and transflective reflectorand is operable to emit or project light therethrough for viewing by aperson viewing the reflective element, and preferably for viewing by aperson viewing the reflective element at an angle with respect to thereflective element.

Turn signal indicator 256 includes a transparent or translucent opticalplastic block 258 and a light control film 260. As shown in FIG. 10A,optical plastic block 258 is disposed at the rear of the substrate 252and at the rear of the transflective mirror reflector 254, with thelight control film 260 disposed between optical plastic block 258 andtransflective mirror reflector 254. Optical plastic block 258 maycomprise a transparent plastic material, such as, for example, anacrylic or polycarbonate or polystyrene material or the like, formedsuch as by injection molding, casting or the like. Turn signal indicator256 includes a plurality of illumination sources 262, such as lightemitting diodes or the like, located at the rear of optical plasticblock 258 and generally at or aligned with a plurality of apertures orpassageways or pipeways 259 formed through block 258 and through whichlight passes without passing through the optical plastic material of theblock itself. However, because of the physical laws of refraction, andbecause of the angles involved, some of the light generated and emittedby each individual light source or light sources 262 passes through thepipeways and some of the light enters the optical plastic material ofthe block and exits other points or areas of the block so that the blockeffectively glows.

Thus, when the light sources are activated, a person viewing thereflective element will see the five beams of relatively intense lightthat passes through the pipeways and a less intense but visiblyappreciable illumination of the block itself around the light beams. Inorder to limit or substantially preclude light leaking or passingthrough the sidewalls of the block so as to be viewable through thereflective element outside of the block shape or footprint (such as anarrow or chevron or the like), the outer walls 258 a of the block 258may be specularly or diffusely reflective or absorbing (such as via acoating or surface finish or the like at the outer walls of the block).Optionally, the rest of the reflective element backing may have anopaque coating or paint or the like (such as an dark or otherwisesubstantially opaque coating or paint or tape or the like) disposed orapplied over the rear of the reflective element except at the displayregion (the area at which the light control film is disposed).

Thus, light emitted by the light sources may pass through the pipewaysin the block and through the block material itself at the rear of thereflective element, whereby the block provides a continuous shape (suchas an arrow or chevron shape or footprint) around the series ofillumination sources so as to provide an illuminated shape emanatingfrom the block and through the mirror reflective element. Light controlfilm 260 may comprise any suitable film and may function asmicrolouvers, so as to preferentially direct light that is received fromone angle whereby the light is redirected or controlled to anotherdirection. An example of a suitable light control film or material isdisclosed in U.S. Pat. No. 5,481,409 (which is hereby incorporatedherein by reference in its entirety), and may comprise a light controlfilm manufactured by the 3M Company of Minn., such as the light controlfilm commercially available under the trade name LCF-P (light controlfilm-polycarbonate). Such a film comprises a thin plastic film enclosinga plurality of closely spaced, light black colored microlouvers. Apreferred light control film is approximately 0.75 mm thick orthereabouts, and the angled microlouvers are spaced approximately 0.127mm apart. The microlouvers may be in various angular positions toprovide a particular viewing angle, such as from as narrow as about a 48degree angle to as wide as about a 90 degree angle. Thus, the lightcontrol film controls or directs the light emitted by the illuminationsources 262, including the light beams passing through the pipeways inthe block as well as the other light emanating from the block materialitself, in a desired or appropriate or predetermined angle with respectto the mirror substrate, and helps assure that the driver of the hostvehicle is largely unaware or not bothered by actuation of thethrough-the-mirror reflector turn signal indicating light sources.

The likes of 3M Light Control Film comprises a thin plastic filmcontaining closely spaced dark or black or light absorbing microlouvers.When used as described herein, the film simulates a tiny Venetian blind,wherein the microlouvers allow for controlled transmission of the lightemitted by the indicator light sources (that are disposed behind thetransflective mirror element) along the axis of the microlouvers so thatthe light is seen by drivers overtaking the host vehicle in a side-laneblind spot area but the line of sight from the driver of the hostvehicle to the turn signal indicator's emitted light beam issubstantially blocked by the microlouvers. Examples of light directingor regulating filters or baffle assemblies can be found in U.S. Pat.Nos. 4,906,085 and 5,313,335, the entire disclosures of which are herebyincorporated by reference herein.

Although shown and described as a turn signal indicator, and with thepipeways allowing the light beams to pass through the block at anoutward angle and the light control film directing the light at anoutward angle away from the vehicle (so as to be principally viewable bya driver of a vehicle approaching or overtaking the subject vehiclewhile being substantially not viewable or discernible by the driver ofthe subject vehicle), the display element may comprise other types ofindicators or displays or illuminated indicia, such as a blind spotdetector system alert or an information display or an approach light orthe like. The angle of the pipeways and of the light control film may beselected depending on the particular application of the display element.For example, for a blind spot detector alert, the block and lightcontrol film may be constructed and arranged so as to direct lighttoward the driver of the subject vehicle. Optionally, a display elementor display elements at a rearview mirror may have a block and lightdirecting film that direct light at different angles so as to providetwo different displays or indicators at the mirror. For example, theblock and light directing film may direct illumination from one or moreillumination sources or LEDs outward away from the vehicle for a turnsignal indicator, and may direct illumination from one or more otherillumination sources or LEDs inward or toward the vehicle for a blindspot detector alert, so that two distinct displays or display types areprovided at the reflective element of the mirror assembly. The twodistinct displays may be provided by a single display element or moduleor may be provided by separate display elements at the rear of thereflective element.

As shown in FIGS. 10A and 10C, pipeways 259 are formed with recesses 259a at the rear or back of the block 258 and angled pipeways 259 b betweenthe recesses 259 a and the front of the block 258. The recesses 259 aare configured to receive or partially receive the illumination sources262, which may be mounted to or established on a printed circuit board264 or the like disposed at or attached to the optical plastic block258. Although shown in FIG. 10A as being loosely positioned at orreceived in the recesses 259 a, it is desirable to have the illuminationsources or LEDs snugly fit in or contacting, and preferably opticallycoupled to, the transparent block 258 so that the illumination from theillumination sources is emitted or projected into the block when theillumination sources are activated.

Optionally, and with reference to FIG. 10D, the mirror reflectiveelement may comprise a transflective electro-optic mirror reflectiveelement 250′, which includes a glass front substrate 252′, a glass rearsubstrate 253′, and a display element or turn signal indicator 256′ atthe rear of the rear substrate 253′. The mirror reflective element 250′comprises an electro-optic, such as electrochromic, reflective elementassembly or cell with an electro-optic medium 255′ (such aselectrochromic medium) disposed between the front and rear substrates252′, 253′. Rear substrate 253′ includes a transflective mirrorreflector 254′ disposed at its front surface (the third surface of thereflective element assembly or cell), while front substrate 252′includes a transparent conductor 257′ disposed at its rear surface (thesecond surface of the reflective element assembly or cell). Theelectro-optic medium 255′ is disposed between the substrates and is incontact with the transparent conductor 257′ and transflective mirrorreflector 254′ and contained between the substrates via a perimeter seal261′. The electro-optic mirror construction may be of an offsetconstruction or a flush or frameless construction or design, such asutilizing aspects of various mirror constructions and designs, such asdescribed herein.

Turn signal indicator 256′ is disposed at the rear of the rear substrate253′ and is operable to emit or project light therethrough for viewingby a person viewing the reflective element, and preferably for viewingby a person viewing the reflective element at an angle with respect tothe reflective element, such as in a similar manner as described above.Although shown in FIG. 10D as having a third surface transflective minorreflector 254′, the transflective mirror reflector may be disposed atthe rear of the rear substrate 253′ (at the fourth surface of thereflective element assembly or cell), with the turn signal indicator256′ disposed at the fourth surface transflective mirror reflector atthe rear surface of the rear substrate. As described above, the turnsignal indicator 256′ includes a transparent or translucent opticalplastic block 258′, a light control film 260′, and a plurality ofillumination sources 262 (preferably LEDs) on a printed circuit board264. Turn signal indicator 256′ may be substantially similar to turnsignal indicator 256, described above, such that a detailed discussionof the turn signal indicators need not be repeated herein. The similarelements of the turn signal indicators not specifically addressed abovewith respect to turn signal indicator 250′ are referenced with likenumbers in FIGS. 10A and 10D.

When manufacturing a printed circuit board (PCB), it is least expensiveand thus desirable to vertically or axially place the LEDs or chips.However, one could choose to have the LEDs put in and angled relative tothe plane of the circuit board. The present invention allows for flatplacement of the LEDs on the circuit board or substrate or chip, whilestill providing an angled direction of light emitted by the LEDs. TheLEDs are thus substantially vertically oriented on the circuit board (solight emitted by the LEDs would be substantially vertical), but theemitted light is piped through the hollow tubes or pipeways in the blockat or near the desired angle or direction for viewing of the lights by aperson viewing the reflective element. Some of the emitted light wouldalso leak into and through the transparent walls of the tubes and blockto provide the substantially solid, continuous illumination or glow inthe desired or appropriate shape around the illumination sources.

The angled pipeways 259 b through optical plastic block 258, 258′ areangled so that light from illumination sources 262 passes through thepipeways at an angle relative to the substrate 252 or substrates 252′,253′, such as at an outward angle (such as for a turn signal indicatorapplication) so as to direct or guide the light outward away from theside of the vehicle when the mirror reflective element is mounted at avehicle, such as at a driver or passenger-side exterior rearview mirrorof a vehicle, so as to be generally not viewable or discernible by thedriver or occupant of the vehicle. For example, for a turn signalindicator application, the pipeways and/or light control film preferablyfunction to angle the light emitted by the illumination sourcesoutwardly away from the subject vehicle such that a driver of anovertaking vehicle would see the display, but the driver of the subjectvehicle would not readily see or discern the display at the mirrorreflective element. The pipeways and/or light control film may beconstructed and/or arranged so as to be angled outward for a turn signalindicator (such as shown in FIGS. 10A and 10D and described above), butcould be otherwise angled inward or downward for other applications(such as for a blind spot detector alert or an approach light or thelike) or could have multiple angles, as discussed below.

Preferably, the optical plastic block 258, 258′ is formed to begenerally arrow-shaped with illumination sources 262 disposedtherealong. As can be seen with reference to FIGS. 10A and 10D, thelight control film 260, 260′ may function to direct or guide the lightgenerally along the same angle as the angled pipeways 259 b (as shown inFIG. 10D), or the light control film may function to direct or guide thelight at a different angle than the angle of the angled pipeways 259 b(as shown in FIG. 10A), without affecting the scope of the presentinvention. By providing the angle of transmission of the light controlfilm as a different angle as compared to the angle of the pipewaysthrough the block, more of the light emitted from the illuminationsources and passing through and along the pipeways may reflect back offof the light control film and/or transmit through the walls, and/orcouple through the walls of the pipeways/tubes and into the block,thereby enhancing the illumination of the block when the illuminationsources are activated and effectively creating a substantially solidilluminated block, such as a solid continuous illuminated chevron orarrow shape or indicia or the like, as opposed to a series of five orseven individual separated discontinuous light sources that are chevronshaped but not forming a solid continuous arrow.

Optionally, the optical plastic block may be formed without anypassageways or pipeways or the plastic block may have pipeways extendingonly partially through the block depending on the desired appearance ofthe display element at the reflective element. Optionally, theillumination sources or LEDs may be located at different areas at theblock, such as at a side of the block (and generally at or aligned withpipeways or at the sidewall of the block), depending on the particularapplication and desired appearance of the display element at thereflective element.

Optionally, and with reference to FIGS. 10E, 10F and 10G, a mirrorreflective element 250″, such as an exterior mirror reflective element,includes a glass or optical plastic substrate 252″ (such as, forexample, a substrate having a thickness of about 2 mm to about 2.5 mm orthereabouts), a transflective mirror reflector 254″ (such as analuminum-doped silicon or an ISI stack, such as an ITO/silver/ITO stackor the like) and a display element, such as a turn signal indicator256″, at the rear of the substrate 252″ and behind the transflectivemirror reflector 254″. Turn signal indicator 256″ includes a lighttransmitting optical plastic block 258″ (that may be specularly lighttransmitting so as to be clear or that may be rendered diffusely lighttransmitting should diffuse light transmission be desired) and a lightcontrol film 260″ (such as a light control film as described above).Turn signal indicator 256″ includes a plurality of illumination sources262″, such as light emitting diodes or diode lasers or incandescentsources or the like, located at the rear of optical plastic block 258″and generally at or aligned with a plurality of recesses or receivingportions 259″ for the light sources at an outer or rearward surface ofblock 258″. The plurality of illumination sources 262 (preferably LEDs)may be established on a printed circuit board 264″ or may be on aflexible polymeric substrate, such as an extruded plastic flat flexiblecable with TPU, PVC or PBT insulation and flat copper connectors (suchas is available from 3M Corporation of Minneapolis, Minn. as FFCeharnesses).

As shown in FIG. 10E, optical plastic block 258″ is disposed at the rearof the substrate 252″ and at the rear of the transflective mirrorreflector 254″, with the light control film 260″ disposed betweenoptical plastic block 258″ and transflective mirror reflector 254″. Asalso shown in FIG. 10E, turn signal indicator 256″ may include a lightabsorbing wall or coating or material 257″ established at and aroundblock 258″ to limit or substantially preclude light from passing throughthe sidewalls of block 258″ to other areas of or at the rear of thereflective element. The light absorbing wall or coating or material 257″may comprise any suitable light absorbing material or layer or element,such as a dark or opaque wall or coating established around the block258″, such as a dark plastic or a black or dark-colored paint, or it maybe a light reflecting but substantially non-light transmitting materialor layer so that any stray light incident on such walls is reflectedback into the body of block 258″. The turn signal indicator 256″ may bepurchased by the mirror element sub-assembly manufacturer (such as froma low cost manufacturer such as in the Far East) and provided as amodular unit having the block and light control film within a lightabsorbing element/structure and with the printed circuit board andillumination sources at the rear surface of the block, and with anyconnectors/covers, etc., so that all the mirror element sub-assemblymanufacturer need do is attach (either mechanically or adhesively,preferably with optical coupling) the bought-in or separatelypurchased/supplied module to the rear of the mirror element. One optionis to use the likes of a PVB (polyvinyl butyral) laminating clear lighttransmitting film or a silicone laminating film or the like and to usethe likes of an autoclave or a vacuum lamination technique (such as isdescribed in U.S. provisional applications Ser. No. 60/732,245, filedNov. 1, 2005; and Ser. No. 60/759,992, filed Jan. 18, 2006, which arehereby incorporated herein by reference in their entireties) tooptically attach the turn signal indicator module at the rear of themirror element. Optionally, a light absorbing coating or material oropacifying material or coating may be established over the rear surfaceof the reflective element at locations other than where the turn signalindicator is located to limit or substantially preclude lighttransmission through the reflective element at regions surrounding theturn signal indicator. In such an application, an opacifying layer orelement may be disposed at the rear of the reflective element and mayhave an opening or aperture or window established at the desired orappropriate location for the turn signal indicator to be located.

As shown in FIG. 10G, optical plastic block 258″ is generallywedge-shaped or angled at its outer or rearward surface (the surfaceopposite from the rear of the reflective element and that has therecesses or receiving portions 259″ for receiving the illuminationsources 262″ therein), so that the principal light axis from theillumination sources is directed at an angle relative to the rearsurface of the reflective element. For example, the block may preferablybe formed with its rear surface (at which the light sources mount) at anangle of about 2 degrees to about 12 degrees or thereabouts (morepreferably, at an angle of about 3 degrees to about 8 degrees orthereabouts and most preferably at an angle of about 3.5 degrees toabout 5.5 degrees or thereabouts) relative to the front surface of theblock (and hence to the rear surface of the mirror element to which theblock engages/attaches). Note also that the front surface of the blockmay be convex contoured to generally match the local (concave) contourof the rear of the mirror element if it is a bent (such as a convex oran aspheric) exterior mirror element. Thus, when the reflective elementis mounted at a vehicle as part of an exterior mirror assembly and isadjusted by a typical driver for rearward viewing at the side of thevehicle, the principal light axis of the illumination sources isdirected away from the driver and principally into the overtaking areaor adjacent lane or blind spot area so as to be readily viewable by adriver of an overtaking vehicle. Note that the angle for the rearsurface of block 258″ may generally match the light control angle oflight control film 260″, or may be somewhat different so that lightcontrol film 260″ somewhat masks the presence of the individual lightsources from view by an observer (whether lit or not lit). Note alsothat a heater pad (not shown) may be present and may have a chevron orother shaped cut out (or alternatively, a light transmitting, optionallylight diffuser) portion that matches and juxtaposes where opticalplastic block 258″ is positioned to the rear of the reflective element.

Optionally, and with reference to FIG. 10H, the mirror reflectiveelement may comprise transflective electro-optic mirror reflectiveelement 250′″, which includes a glass front substrate 252′″, a glassrear substrate 253′″, and a display element or turn signal indicator256′″ at the rear of the rear substrate 253′″. The mirror reflectiveelement 250′″ comprises an electro-optic, such as electrochromic,reflective element assembly or cell with an electro-optic medium 255′″(such as electrochromic medium) disposed between the front and rearsubstrates 252′″, 253′″. Rear substrate 253′″ includes a transflectivemirror reflector 254′″ (such as a thin transflective silver orsilver-alloy or aluminum or aluminum-alloy or metal oxide/metal/metaloxide transflective coating stacks such as ITO/Ag/ITO or AZO/Ag/AZO)disposed at its front, inner-facing surface (the third surface of thereflective element assembly or cell), while front substrate 252′″includes a transparent conductor 257′″ (such as ITO or AZO or doped tinoxide) disposed at its rear surface (the second surface of thereflective element assembly or cell). The electro-optic medium 255′″ isdisposed between the substrates and is in contact with the transparentconductor 257′″ and transflective mirror reflector 254′″ and containedbetween the substrates via a perimeter seal 261′″. The electro-opticmirror construction may be of an offset construction or a flush orframeless construction or design, such as utilizing aspects of variousmirror constructions and designs, such as described herein. The mirrorreflective element may include a heater pad disposed at its rearsurface, and the heater pad may have an aperture or window or holeestablished at the display area for the turn signal indicator to projector emit light therethrough.

As shown in FIG. 10H, turn signal indicator 256′″ includes an opticalplastic block 258′″, light control film 260′″, a plurality ofillumination sources 262′″ and a printed circuit board 264′″, such as ina similar manner as described above. Mirror reflective element 250′″includes a molded backplate 270′″ attached or adhered to the rearsurface of rear substrate 253′″ with actuator mounting elements 270 a′″for mounting the mirror reflective element to a mirror actuator of theexterior mirror assembly, such as in a known manner. Backplate 270′″includes a receiving pocket 270 b′″ molded or formed at a desired orappropriate location at the backplate for receiving the turn signalindicator 256′″ therein. As can be seen in FIG. 10H, the light controlfilm 260′″ and optical block 258′″ may be received within pocket 270 b′″with illumination sources 262′″ and printed circuit board 264′″established at the outer or rearward surface of block 258′″. Preferably,the turn signal indicator 256′″ may be provided as a modular unit(including the block, light control film, illumination sources andprinted circuit board assembled together into a unitary module) andinserted into or received in the pocket 270 b′″ at the rear of themirror reflective element (and held therein, such as mechanically oradhesively). However, rather than being provided as a preassembledmodule, the block, light control film and illumination sources(preferably LEDs) on the printed circuit board may be providedindividually and assembled to the mirror reflector individually.Optionally, the minor reflective element may include a diffuser ordiffusing window or layer and/or the block itself may be diffusing orslightly diffusing of the light passing therethrough.

The backplate 270′″ thus has a pocket 270 b′″ surrounding an apertureformed through the backplate and receiving the turn signal indicator256′″ therein. The aperture and pocket thus may be arrow-shaped orchevron-shaped and may receive a correspondingly shaped or formed turnsignal indicator. The pocket 270 b′″ is defined by walls extendingrearward or outward from the backplate to substantially encase orsurround the optical block 258′″ when inserted into the pocket 270 b′″.

Thus, the backplate may be attached or adhered to the rear surface ofthe reflective element and the turn signal indicator may be insertedinto or slid into the pocket. The turn signal indicator desirably may beprovided as a modular unit (including the block, light control film,printed circuit board and illumination sources) that is readily insertedinto the pocket and electrically connected to electrical circuitry ofthe reflective element and/or mirror assembly. The turn signal indicatormodule thus may be purchased and provided as a separate modular unitthat is readily installed or attached at the rear of the reflectiveelement, such as at the mirror manufacturer's assembly facility orplant.

Optionally, the light control film may be diffusing or partiallydiffusing, or the turn signal indicator may include a separate diffuseror the block itself may comprise a diffusing material. Optionally, adiffuser is not included, and optionally, the turn signal indicator maynot include the light control film. The turn signal indicator may bemechanically attached or secured at the pocket and may include orprovide optical coupling of the block and/or light control film with therear surface of the reflective element, such as via an optical adhesiveor the like. Optionally, the individual elements of the turn signalindicator may be inserted into or established in the pocket to assemblethe turn signal indicator in the pocket.

Optical plastic blocks 258″, 258′″ may be otherwise substantiallysimilar to blocks 258, 258′, described above, such that a detaileddescription of the optical blocks need not be repeated herein. Similarto optical plastic block 258, described above, optical plastic blocks258″, 258′″ may comprise a transparent plastic material, such as, forexample, an acrylic or polycarbonate or polystyrene material or thelike, formed such as by injection molding, casting or the like. Also,and similar to the optical blocks described above, optical block 258″,258′″ may be generally arrow-shaped to provide a substantially solidilluminated arrow at the reflective element when the illuminationsources are activated. As can be seen in FIGS. 10E, 10G and 10H, blocks258″, 258′″ may be wedge-shaped, and may have narrower or thinner outerleg portions as compared to a thicker center or arrow head portion.Optionally, and as can be seen in FIGS. 10E, 10G and 10H, theillumination sources may be located at recesses 259″, 259′″, withoutpipeways formed through the block as described above. The block may besubstantially transparent and may diffuse the light passingtherethrough.

Note that one advantage of the embodiments above is that light sourcessuch as LEDs can be axially mounted onto PCBs and any angling of theirorientation to the rear of the reflective element is via the angling ofthe rear surface of the optical block. This facilitates economy ofmanufacture as the PCB manufacturer may use automatic chip placementmachines to axially (i.e. generally perpendicular to the surface of thePCB substrate) insert the likes of surface-mount LEDs (and without theneed to insert at an angle or to angle the LEDs in a post-insertionoperation). Also, though illustrated as a turn signal indicator, theadvantages of the above embodiments may also be achieved with a blindspot detection system indicator (and where the angling of the rearsurface of the optical block and of the light control film is towardsthe driver/cabin of the host vehicle when the reflective element ismounted in the exterior mirror assembly of the host vehicle). Also, acombined turn signal/blind spot indicator may be formed with portions ofthe optical block (and of the optical control film, if present) angledaway from the cabin of the host vehicle for the turn signal function andtowards the cabin of the host vehicle for the blind spot detectionindicator function. Also, such angling of the rear surface of theoptical block is also applicable should light transmitting channels ortubes be created at least partially through the block, such as shown inFIGS. 10A, 10C and 10D (and note that should such channels or tubes bepresent, the rest of the block may be formed of a light absorbingmaterial, such as of a dark-pigmented polymeric material or of a lightdiffusing material).

Also, note that optionally, the optical control film may be disposed atthe rear surface of the optical block (rather than disposed between theblock 258, 258′, 258″ or 258′″ and the rear surface of the mirrorreflective element such as shown in FIGS. 10A, 10D, 10E and 10H), whileremaining within the spirit and scope of the indicator of the presentinvention. For example, and as shown in FIG. 10I, the turn signalindicator 256″″ includes an optical plastic block 258″″, with a lightcontrol film 260″″ established (such as via adhering or otherwiseattaching) at its rear surface, and with a plurality of illuminationsources 262″″ and a printed circuit board 264″″ at the rear of the blockand film. Optionally, and desirably, the indicator 256″″ includes anopaque wall or tape or material 257″″ at and around the optical block258″″, such as described above. As can be seen in FIG. 10I, the lightcontrol film 260″″ has its micro louvers 260 a″″ at about zero degrees(i.e., generally perpendicular to the plane of the light control film)so as to direct the principle beam axis 261″″ of the light emitted bythe illumination sources at the desired or appropriate angle establishedby the angling of the rear surface of the block relative to its frontsurface and so have the light beam emitted by the light sources passthrough the block 258″″ and through the substrate 252″″ of thereflective element 250″″ to exit at an angle. Because the light controlfilm 260″ is established at the rear surface of the block 258″″, theblock may not include recesses to receive the light sources, butoptionally, the light control film may be laminated (at an angle)between a lower block portion (that has an angled rear face) and anupper block portion, and with such recesses provided in the upper blockportion. The block can optionally include light transmitting pipewaystherethrough (such as pipeways described above with respect to blocks258, 258′, 258″, 258′″).

As shown in FIG. 101, the rear surface of the block may be angledrelative to the forward surface of the block at the rear of thereflective element, and may be substantially flat or planar, with thelight control film established thereat, and with the illuminationsources and printed circuit board located at the rear of the lightcontrol film so as to direct or emit illumination through the lightcontrol film and through the transparent block and further through thetransflective reflective element at an angle set by the slanted rearface of the block. The angle of the rear surface of the block and theangle of the micro louvers thus may be selected to provide the desiredangle of the principle beam axis of the light emitted by the indicator.However, and as shown in FIG. 10I, it is desirable in such aconfiguration to use light control film with zero degree louvers. Turnsignal indicator 256″″ may be otherwise substantially similar to theturn signal indicators 256, 256′, 256″, 256′″ described above, such thata detailed discussion of the turn signal indicators need not be repeatedherein. Although shown in FIG. 10I as being established at a rear of asubstrate 252″″ of a non-electro-optic transflective reflective element,the indicator 256″″ (with the light control film established at the rearof the optical block) may be implemented at the rear of an electro-opticreflective element, such as described above with respect to indicators256′ and 256′″, and the indicator may be received or inserted into apocket at a backplate or the like of the reflective element).

Placement of the light control film on the angled rear surface of theoptical block is advantageous when the light control film (such as 3M'sVikuiti™ ALCF-P or LCF-P) is used where the louver angle is zero degreesand where on-axis vertically incident light from the light sources ishighly transmitted but where off-axis light is cut-off by the embeddedmicro louvers. Such zero degree louvered light control film is used forprivacy filters for laptop computer screens and ATM screens; and so iseconomically available. By being able to purchase and use zero anglelouvered light control film as shown in FIG. 10I, but by using the likesof an angled optical block to support the light control film at an anglein front of the light sources that are similarly angled and supported,economical assembly can be enhanced [or, alternatively, by using amechanical support to mutually support and angle the light controlfilm/light sources relative to the plane of the rear of the mirrorreflective element, so that light emitted by the light sources isgenerally aligned with or on-axis with the light transmission axisbetween the louvers, and so that the light beam passed through the lightcontrol film impinges on the mirror reflective element and passestherethrough with its principal beam axis directed away (for a turnsignal indicator) from the vehicle body side and away from direct viewby a driver of the host vehicle to which the exterior minor reflectiveelement is attached].

Economy of assembly and supply can be achieved by utilizing theembodiment such as shown in FIG. 10H. The combination of a mirrorbackplate that is adapted to receive a turn signal indicator module (ora blind spot indicator module or an approach light module) incombination with a transflective mirror reflective element can optimizethe cost for the minor assembly supplier as follows. The minor assemblysupplier (which may be the Tier 1 supplier to the automaker) can make orprocure the transflective mirror element. Separately, the minor assemblysupplier can make or procure the mirror backplate. Separately, themirror assembly supplier can make or procure the turn signal module (orits sub-components). Then, the mirror assembly supplier (or asub-assembly supplier thereto) can take the transflective minor elementand attach a heater pad to its rear (with an aperture or a lighttransmitting window, preferably a light diffuser and transmitter,created therein that matches, for example, the chevron shape anddimensions of the turn signal indicator module that will be used). Thenthe backplate (that is modified to receive the turn signal module suchas is shown in FIG. 10H) can be attached (such as via a tape adhesive orthe like). Then the turn signal indicator module may be inserted intothe pocket at the backplate, and any cap or cover may be attached andthe assembly of the mirror element with indicator feature is achieved.

There are several benefits to using a transflective mirror reflector forsuch a through-the-mirror-reflective element turn signal feature (orother indication or lighting feature). Currently, the likes of a GeneralMotors GMT 800 driver-side exterior mirror assembly is equipped with anelectrochromic mirror element that has a signal light area formed in itsreflective coating by removing a portion of the reflective coating andaligning the signal light with this signal light area. The portionremoved is laser ablated to leave lines devoid of reflective materialseparated by lines of the reflective material in a non-transflectivemirror reflector that is deposited onto the third surface of theelectrochromic mirror element used (such as is disclosed in U.S. Pat.No. 6,111,683, the entire disclosure of which is hereby incorporated byreference herein).

The embodiment illustrated in FIG. 10H and disclosed herein has severaladvantages and improvement over these existingthrough-the-mirror-reflective element turn signal electrochromicmirrors. For example, use of a third surface transflective mirrorreflector instead of a third surface mirror reflector whereholes/apertures/jail-bar lines/ablations/micro-ablations or the like arecreated has the benefit that there are no consumer viewable openingssuch as holes/apertures/jail-bar lines/ablations/micro-ablations presentin the mirror reflector's coating(s). Thus, should the automaker orconsumer elect not to use the turn signal feature, the turn signalmodule may be left out but the common backplate [where the receivingstructure for the turn signal module/components can be economicallycreated during the injection molding of the backplate from a polymericresin (such as ABS or PC/ABS or the like)] and heater pad may still beused. This is because with a transflective reflector, there are novisible holes or ablations or lines of the like visible to the consumerthat betray that there is now no turn signal indicator present. Thus,use of a third surface transflective mirror reflector in such anelectrochromic through-the-mirror-reflective element turn signal featureallows the Tier 1 mirror maker and/or the automaker elect to supply abase or turn-signal featured electrochromic mirror assembly using acommon assembly process.

As a further advantage, use of a third surface transflective mirrorreflector has the advantage that there is no need to align the lightsources (such as the 5 or 7 LEDs in a turn signal chevron) of the turnsignal unit/module with holes or apertures in the mirror reflector. Andby having the receiving structure/elements for the turn signal module bemolded into the plastic backplate itself, the turn signal alignment andpositioning to the rear of the mirror element is accurately establishedin the precise attachment of the backplate to the rear of the mirrorelement (an operation that the mirror element sub-assembly maker has todo in any event so that the mirror sub-assembly correctly receives theminor element-positioning actuator).

Thus, and in accordance with embodiments above, a transparent orsubstantially transparent optical plastic block may be formed in thegeneral shape of an arrow so that the arrow is viewable and discernibleby a person viewing the reflective element. The light emitted throughthe pipeways in the block and through the light control film may beviewed (such as at or near the angle of the directed or guided light) asrelatively intense points of light or light sources when theillumination sources are activated, while the transparent block(preferably in the shape of an arrow or other suitable shape or form)will be viewable as a solid shape (such as an arrow shape or the like)around the light sources to provide an image of the arrow and not justthe individual points of light. When the illumination sources areactivated, light emitted by the illumination sources is guided throughand along the angled pipeways through the block and may be refracted orguided or controlled by light control film so as to be directed in adesired direction, such as outwardly away from the vehicle. Thus, theillumination sources and the illuminated block are readily viewable by adriver of another vehicle adjacent or approaching the subject vehicle,while the illumination is not readily viewable or discernible by thedriver of the subject vehicle.

The transflective mirror reflector (such as at the rear of the singlesubstrate or at the front surface of the rear substrate of theelectro-optic reflective element assembly or cell) may comprise anysuitable transflective mirror reflector or coating or layer or layers,such as those described herein. For example, and in a preferredembodiment, the transflective mirror reflector may comprise a siliconmaterial or a doped silicon material or the like, preferably having arefractive index (as measured at the sodium D line) of at least about 3or thereabouts. For example, good results have been achieved bysputtering from a silicon-aluminum sputtering target (e.g. 95%/5% Si:Al)or the like. In such an embodiment, a sputter coating of a physicalthickness (sputtered in an argon atmosphere) of about 200 to 300angstroms or thereabouts exhibits a first surface reflectivity of about60-65% R photopic reflectivity (as measured per SAE J964a), and a secondsurface reflectivity of about 50-55% R, and a photopic transmission ofaround 18 to 20% T or thereabouts. The coating may be deposited ordisposed on a flat or substantially flat substrate (and optionally,subsequently bent in a glass bender thereafter), or may be deposited ordisposed on a curved substrate, such as a curved substrate of the typeshown in FIG. 14 and discussed below. Other transflective mirrorreflectors may be implemented depending on the particular application.Optionally, the substrate may include a reflective perimeter band aroundits perimeter, such as described below with respect to FIG. 14, so thata single substrate mirror reflective element may be used at an oppositeside of the vehicle (such as the passenger-side of the vehicle) inconjunction with an electro-optic reflective element assemblyimplemented at the other side of the vehicle (such as the driver-side ofthe vehicle) that may include such a perimeter reflective band toprovide a frameless reflective element, such as described herein.

Optionally, and particularly for exterior mirror applications, thereflective element may include a broader perimeter band at the area orregion where a display element is located. For example, and withreference to FIG. 11, an exterior mirror reflective element 310 mayinclude a perimeter band 326 around the perimeter or border of thereflective element. The perimeter band 326 has a broader band portion326 a along a perimeter portion of the reflective element 310 and alongan area that has one or more display elements 330. The display elements330 may comprise illumination sources or light sources, such as lightemitting diodes (LEDs) or the like, and may be positioned behind therear surface of the reflective element and directed to emit illuminationthrough the reflective element and through the broader band portion 326a of perimeter band 326. The broader band portion 326 a may have one ormore windows or ports 327 a formed or established through the bandportion and generally at or aligned with the display elements 330, orthe perimeter border band 326 (or at least the broader band portion 326a of perimeter band 326) may be passively transflective (such as a bandformed or established by a layer of a silicon material or the like) toallow light from the display element or elements 330 to pass through thereflective element and the perimeter band (optionally, the perimeterband may have a higher transmissivity characteristic than theelectro-optic area of the reflective element to enhance viewability anddiscernibility of the light emitted by the display elements) so as to beviewable by a person viewing the reflective element. For example, andsuch as is described in U.S. Pat. No. 6,065,840, which is herebyincorporated herein by reference in its entirety, a sputtered siliconthin film (with a physical thickness in a range of about 300 angstromsto about 450 angstroms) can have a photopic reflectivity greater than atleast about 50 percent, and more preferably greater than at least about55 percent of light incident thereon, and having a transmission valuegreater than at least about 15 percent, and more preferably greater thanat least about 20 percent of light incident thereon.

Optionally, the reflective element 310 may include a photo sensor 340for sensing light at the reflective element. In the illustratedembodiment, the photo sensor 340 is located at and behind the perimeterband 326, and at a broader region 326 b of perimeter band 326. The photosensor 340 may be directed or angled or oriented so as to be facinggenerally upward or skyward to detect light above the reflectiveelement. The perimeter band portion 3261) may have a window or port 327b formed therethrough to allow light to pass through the perimeter bandportion 326 b to the photo sensor 340.

The reflective element 310 may comprises a transflective or display ondemand type of reflective element with a perimeter seal around theperimeter of the reflective element and, thus, around the perimeter ofthe electro-optic area of the mirror reflective element. The perimeterband may be disposed (such as on the second surface of the frontsubstrate as described above) around the perimeter of the substrate soas to conceal the perimeter seal (such as described in PCT ApplicationNo. PCT/US03/29776, filed Sep. 19, 2003 by Donnelly Corp. et al. forELECTROCHROMIC MIRROR ASSEMBLY; and/or PCT Application No.PCT/US03/35381, filed Nov. 5, 2003 by Donnelly Corp. et al. forELECTRO-OPTIC REFLECTIVE ELEMENT ASSEMBLY; and/or U.S. patentapplication Ser. No. 11/021,065, filed Dec. 23, 2004, now U.S. Pat. No.7,255,451; Ser. No. 10/528,269, filed Mar. 17, 2005, now U.S. Pat. No.7,274,501; Ser. No. 10/533,762, filed May 4, 2005, now U.S. Pat. No.7,184,190; Ser. No. 11/226,628, filed Sep. 14, 2005 (Attorney DocketDON01 P-1236); and/or Ser. No. 11/021,065, filed Dec. 23, 2004, now U.S.Pat. No. 7,255,451; and/or U.S. provisional applications Ser. No.60/692,113, filed Jun. 20, 2005; Ser. No. 60/677,990, filed May 5, 2005;Ser. No. 60/653,787, filed Feb. 17, 2005; Ser. No. 60/642,227, filedJan. 7, 2005; Ser. No. 60/638,250, filed Dec. 21, 2004; Ser. No.60/624,091, filed Nov. 1, 2004, and Ser. No. 60/609,642, filed Sep. 14,2004, which are hereby incorporated herein by reference in theirentireties). The display elements 330 and/or photo sensor 340 may bepositioned outboard of the perimeter seal so that they are not locatedin the electro-optic area of the reflective element. Because the displayelements and/or photo sensor are positioned at the perimeter band area,they are not invasive of the electro-optic function of the reflectiveelement. Thus, the display elements may be positioned at the reflectiveelement for emitting illumination through the reflective element,without the extra complexities of the electro-optic or electrochromictransflective function. Also, the photo sensor may be positioned at thereflective element for receiving light external to the reflectiveelement, without having to form a window or aperture in the reflectivecoatings of the transflective reflective element.

Optionally, and with reference to FIGS. 12 and 13, a mirror reflectiveelement 310′ may include a wide angle or auxiliary mirror or reflector350 at a perimeter region or corner region of the reflective element toprovide a rearward wide angle view to the driver of the vehicle. Thewide angle reflector may be established at the reflective element andbehind the fourth surface of the reflective element, such as byutilizing aspects of the reflective elements described in U.S. Pat. No.6,315,419 and/or U.S. pat. publications, Pub. No. US 2002/0105741,published Aug. 8, 2002; and/or US 2003/0117731, published Jun. 26, 2003;and/or International Pub. No. WO 01/81956, published Nov. 1, 2001, whichare all hereby incorporated herein by reference in their entireties. Thewide angle reflector may be positioned at a perimeter region of thereflective element so as to provide a wide angle viewing area forviewing the blind spot area at the side and rearward of the vehicle,while the primary or central region of the reflective element provides agenerally planar reflective surface for viewing rearward and sideward ofthe vehicle mirror.

The reflective element 310′ includes a perimeter band 326′ around theperimeter of the reflective element and a perimeter band portion 326 a′inboard of a wide angle area or region 352 at the reflective element andaround an inboard perimeter region of the wide angle reflector 350. Theperimeter band thus separates and/or demarcates the wide anglereflective portion from the generally planar reflective portion of thereflective element, and may conceal or hide the edges of the wide anglereflector. As can be seen with reference to FIG. 13, the perimeter band326′ is disposed on the second surface 312 a of the front substrate 312and generally at or along the perimeter seal 322 of the reflectiveelement 310′, while the perimeter band portion 326 a′ is disposed on thesecond surface 312 a and inboard of the seal 322 to generallyoutline/demarcate an inner perimeter of the wide angle reflector 350.The perimeter band portion 326 a′ may have generally the same width asthe perimeter band 326′, or may have a reduced width or narrow width toreduce the effect on the viewing area of the reflective element.

Wide angle reflector 350 is positioned at the rear (or fourth) surface314 b of rear substrate 314 and may be adhered to rear surface 314 b andgenerally behind the wide angle area 352 defined by the perimeter band326′ and perimeter band portion 326 a′. In the illustrated embodiment,wide angle reflector 350 comprises a substantially clear, transparentoptical plastic member 354 (such as, for example, an acrylic orpolycarbonate or COC or CR39 or the like) and a reflective coating orlayer or adhesive or film 356. Optical plastic member 354 has asubstantially flat mating surface 354 a and a curved face 354 b oppositeto the mating face 354 a. Reflective film 356 may be adhered orotherwise attached to curved face 354 b so as to establish a curvedreflective surface 356 a. Wide angle reflector 350 may be adhered to orotherwise attached to rear surface 314 b of rear substrate 314, such asvia an optical adhesive 358, such as an optical epoxy or acrylicmaterial. The optical adhesive may be substantially optically matched tothe reflective element substrates, so that the refractive index of theoptical adhesive is substantially similar to the refractive index of theglass substrate (such as at about 1.52 refractive index), such as byutilizing aspects of the reflective element described in U.S. patentapplication Ser. No. 10/993,302, filed Nov. 19, 2004, now U.S. Pat. No.7,338,177, which is hereby incorporated herein by reference in itsentirety.

Thus, the wide angle reflector may be positioned at the rear surface ofthe reflective element and may reflect light from a wide angle view tothe driver of the vehicle to assist the driver in viewing the blind spotarea at the side of the vehicle. The reflective element may comprise anelectro-optic reflective element with a transparent conductive coatingor layer 318 at the rear surface 312 a of the front substrate 312 and athird surface reflective coating or layer (or layers) 320 b at the frontsurface 314 a of the rear substrate 314, and with an electro-optic orelectrochromic medium 316 disposed therebetween. As can be seen in FIG.13, the third surface reflective coating or layer 320 b (such as a layerof chromium or ruthenium or rhodium or ruthenium/chromium orrhodium/chromium or other suitable layer or coating) may be removed ornot established at the wide angle reflector area, and a transparentconductive coating or layer 320 a may be disposed over the thirdsurface, including the wide angle reflector area, so that theelectro-optic feature may function in that area. A window or port ornon-reflective region 321 thus may be formed in the third surfacereflector (so as to provide a window or area that is substantiallydevoid of the reflective coating or coatings) to enhance the lighttransmissivity therethrough (such as by ablating or masking the area toremove or not establish the reflective coating or coatings at the wideangle reflector area). The front surface of the rear substrate thus mayhave the transparent conductive coating 320 a over its entire surface,with the wide angle reflector area being masked during the deposition orcoating of the third surface reflective coating or coatings so that thereflective coatings are not deposited or established at the wide angleviewing area (or the reflective coatings may be removed or ablated afterthe coating process). The wide angle reflector thus may be disposedbehind the electro-optic medium so as to provide the wide anglereflective field of view through the electro-optic medium.

Optionally, the perimeter seal may be disposed around the perimeter ofthe reflective element and along the wide angle perimeter band portion326 a′ so that the wide angle area 352 is devoid of the electro-opticmedium (and may be devoid of the third surface reflector layers orcoatings in that area as well) to enhance light transmissivity throughthe reflective element in the wide angle viewing area. In such anapplication, the transparent conductive coating may also be removed fromthe wide angle reflector area, such that the coatings or layers in thatarea may be readily removed or not established, such as by laserablating or masking or the like.

Optionally, the perimeter band (and/or any indicia or display elementsor the like as described above) may be established at a rear surface ofa curved or bent substrate, such as for a passenger-side exterior mirrorof a vehicle. For example, and with reference to FIG. 14, a curvedreflective element 410 includes a bent or curved substrate 412 (such asa convex or aspheric substrate) and a reflective coating or layer 418disposed or established at the rear surface 412 a of substrate 412. Aperimeter border or band 426 (such as chromium or other suitablematerial) may be disposed around the perimeter region of the reflectiveelement, such as directly on the rear surface of the substrate 412 (asshown in FIG. 14) or over the reflective coating at the perimeter region(so that the reflective coating is between the perimeter band and therear surface of the substrate), such as described above.

The reflective coating or layer may comprise a metallic reflectivematerial or may comprise transflective materials, such as a silicon orindium/silver material or an interference stack, such as anSiO₂/TiO₂/SiO₂ stack of layers or the like (such as by utilizing aspectsof the reflective elements described in PCT Application No.PCT/US03/29776, filed Sep. 9, 2003 by Donnelly Corp. et al. for MIRRORREFLECTIVE ELEMENT ASSEMBLY; and/or PCT Application No. PCT/US03/35381,filed Nov. 5, 2003 by Donnelly Corp. et al. for ELECTRO-OPTIC REFLECTIVEELEMENT ASSEMBLY; and/or U.S. patent application Ser. No. 11/021,065,filed Dec. 23, 2004, now U.S. Pat. No. 7,255,451; Ser. No. 10/528,269,filed Mar. 17, 2005, now U.S. Pat. No. 7,274,501; Ser. No. 10/533,762,filed May 4, 2005, now U.S. Pat. No. 7,184,190; Ser. No. 10/993,302,filed Nov. 19, 2004, now U.S. Pat. No. 7,338,177, which are herebyincorporated herein by reference in their entireties). As shown in FIG.13, a protective coating 438 (such as a lacquer or paint, which may besubstantially transparent if the reflective element is a transflectivereflective element) may be disposed over the reflective coating 418 toprotect the reflective coating.

Typically, it is desired that the appearance of the mirror reflectiveelements of the exterior rearview minors of a vehicle match orsubstantially match between the driver-side and passenger-side rearviewmirrors of a vehicle, so that, for example, for a vehicle with adriver-side electro-optic reflective element and a passenger-sidenon-electro-optic reflective element, the bleached (or non-colored ornon-darkened) appearance of the driver-side mirror reflector matches orsubstantially matches the appearance of the non-electro-opticpassenger-side mirror reflector. A person viewing the vehicle, such asin a vehicle showroom or at a parking lot or the like, or while thevehicle is being driven along a road, thus may view and discern thatthat the mirror reflector at the driver-side mirror matches orsubstantially matches the mirror reflector at the passenger-side mirror.

When both the driver and passenger-side rearview mirrors are selected tohave the same type of reflective element (such as a framelesselectro-optic reflective element using a border, non-dimming metallicreflective band, such as, for example, a frameless electrochromicreflective element as described above), such symmetry of appearance isreadily achieved. However, it is not unusual, for economy purposes, toprovide an electro-optic reflective element at the driver-side exteriorrearview mirror and a non-electro-optic reflective mirror at thepassenger-side exterior rearview mirror. When an electro-opticdriver-side exterior rearview mirror is implemented on a vehicle with anon-electro-optic passenger-side exterior rearview mirror (as is oftenselected to reduce costs associated with the mirror assemblies of thevehicle), it is still typically desired that the reflective elements ofthe side rearview mirrors substantially or fully match in appearance toprovide a similar appearance or style at the mirror at both sides of thevehicle, such as for aesthetic purposes. Thus, it is desired that theappearance of the non-electro-optic reflective element of thepassenger-side rearview mirror substantially or fully match theappearance of the electro-optic reflective element of the driver-siderearview mirror, such as when the electro-optic reflective element is inits bleached or non-powered or non-darkened state (such as during highambient lighting or daytime lighting conditions).

The perimeter band material thus may be selected to substantially matchthe appearances between the driver-side exterior mirror (which maycomprise an electrochromic mirror with a perimeter band around theperimeter to conceal the perimeter seal of the reflective element) andthe passenger-side exterior mirror (which may comprise anon-electrochromic mirror), so that both mirrors provide a similarappearance to the perimeter band and reflective element. Forapplications where the perimeter band material of the electrochromic ordriver-side mirror is selected to be the same as the third surfacereflector material, the optical match (as viewed by a person viewing thereflective element) between the perimeter band and the third surfacereflector is sufficient so that the perimeter band is not readilydiscernible at the mirror reflector. Thus, in such applications, it maynot be necessary to provide a perimeter band on the correspondingconventional (such as chrome or titanium or “Blue” coated), non-ECpassenger-side exterior mirror reflective element.

However, even in such applications, the perimeter band at thedriver-side mirror may be discernible to a person viewing the exteriormirror, even when the perimeter band is substantially optically matchedwith the central reflector region of the reflective element. Thus, inorder to at least substantially match the passenger-sidenon-electro-optic reflective element with the electro-optic reflectiveelement at the driver-side mirror, a perimeter band or coating (forexample, a layer of chromium or of rhodium or of rhodium/chromium) maybe disposed around the perimeter edge or region of the non-electro-opticreflective element, such as a curved single substrate reflective elementor the like. Thus, when one exterior side rearview mirror has anelectro-optic reflective element (as is typically located at thedriver-side of the vehicle) and the other exterior side rearview mirrorhas a curved reflective element or non-electro-optic reflective element(as may be provided at the passenger-side of the vehicle), a matchingperimeter band may be disposed around the non-electro-optic reflectiveelement so that the perimeter band of the passenger-side mirror matchesor substantially matches the perimeter band of the driver-side mirror(such as by utilizing aspects described in U.S. patent application Ser.No. 11/226,628, filed Sep. 14, 2005 (Attorney Docket DON01 P-1236),which is hereby incorporated herein by reference in its entirety).

Such a matching appearance of the non-electro-optic reflective elementwith the frameless electro-optic reflective element (with perimeter bandas described above) may be achieved via various processes. For example(and such as described above and shown in FIG. 14), a perimeterreflective border may comprise a first metallic reflective layer (suchas a metallic border or band, such as a ruthenium metal or the like) andmay be disposed around the perimeter region of the second surface of thecurved glass substrate (such as by sputter deposition or the like of theborder material over the second surface of the substrate while thecentral region or primary viewing area of the second surface of thesubstrate is masked). A reflective layer or coating of a second metalreflector material (such as chromium or the like) may be disposed overthe second surface and over the perimeter border or band to provide thecentral reflective region with a reflective perimeter border or band fora frameless non-electro-optic reflective element (such as by utilizingaspects described in U.S. patent application Ser. No. 11/226,628, filedSep. 14, 2005 (Attorney Docket DON01 P-1236); Ser. No. 10/533,762, filedMay 4, 2005, now U.S. Pat. No. 7,184,190; and/or Ser. No. 11/021,065,filed Dec. 23, 2004, now U.S. Pat. No. 7,255,451, and/or U.S.provisional applications Ser. No. 60/681,250, filed May 16, 2005; Ser.No. 60/690,400, filed Jun. 14, 2005; Ser. No. 60/695,149, filed Jun. 29,2005; Ser. No. 60/730,334, filed Oct. 26, 2005; and Ser. No. 60/750,199,filed Dec. 14, 2005, which are hereby incorporated herein by referencein their entireties. Optionally, and desirably, the percent reflectivityof the second metallic reflective layer is less than the percentreflectivity of the first metallic reflective layer. Optionally, thereflective material and thickness of the material layer at the perimeteror border region of the reflective element may be selected to provide adesired spectral reflectivity so as to match or substantially match thespectral reflectivity and appearance of the central region or mainreflective region or dimming region of the electro-optic reflectiveelement when the electro-optic reflective element is in its bleached ornon-powered or non-darkened/non-colored state.

Optionally, the appearance of a matching perimeter band (that matches aperimeter band of an electro-optic reflective element, such as aperimeter band that substantially matches the color or tint of thecentral reflective region of the electro-optic reflective element whenbleached) may be achieved by establishing a demarcation line along andthrough the reflective coating of a single substrate, so that thedemarcation line appears to be an inward perimeter edge of a reflectiveperimeter band or border. For example, and as shown in FIGS. 15A and15B, a reflective element 510, such as a generally planar reflectiveelement or a curved reflective element for an exterior rearview mirror,includes a substrate 512 (such as a glass substrate, such as a generallyflat substrate or a bent or curved substrate, such as a convex oraspheric substrate) and a reflective coating or layer 518 (such as amirror reflector coating or coatings comprising, for example, chromiumor titanium or silver or aluminum or silver alloy or aluminum alloy or astack of layers, such as an ITO/silver/ITO stack of layers, or like)disposed or established at the second or rear surface 512 b of substrate512 (opposite the first or front or viewable surface 512 a of thesubstrate 512), such as by sputter deposition in a vacuum depositionchamber, such as is known in the coating arts. As shown in FIG. 15B, aperimeter or border reflector region 526 may be outlined or demarcatedor defined by a demarcation line 526 a established (such as by laseretching or the like) through the reflective coating or layer 518 at theperimeter region. The reflective element 510 thus has a central mainreflector region 524 and the perimeter or border reflector region 526separated or defined or circumscribed by demarcation line 526 a.

Thus, a mirror substrate or shape (such as a glass substrate or shape)may be cut from a sheet of glass to the desired mirror shape. The mirrorsubstrate may be uniformly coated (with no masking) over at leastsubstantially or entirely the second or rear surface of the substrate toprovide a substantially uniform reflective coating or layer at thesecond surface of the substrate. Optionally, a sheet of glass or thelike may be substantially uniformly coated over a surface of the sheet,and one or more coated minor substrates or shapes may be cut from thecoated glass sheet to provide the mirror substrate with the reflectivecoating or layer at the second surface of the substrate. The demarcationline then may be established (such as via laser etching or the like)around the perimeter of the cut and coated substrate so as tocircumscribe and run around substantially or wholly the perimeter regionof the cut substrate or shape. The demarcation line and perimeter orborder reflector region and central main reflector region of thereflective element thus may be established via a single, unmaskedcoating process. The demarcation line may be established at a range ofabout 2 mm to about 5 mm (or more or less) inward from the perimeter cutedge of the substrate, whereby the width of the demarcation line may beselected to match or substantially match the border or perimeter band onthe electro-optic reflective element at the driver-side mirror.

As shown in FIG. 15B, a coating or layer or overcoating 538 (such as alacquer or paint or frit or tape or appliqué or coating) may be disposedover the reflective coating 518 to cover or coat the rear surface of thereflective element. The coating or layer may be painted or pad printedor screened or inked or otherwise applied or disposed or established atthe rear surface of the reflective element. Optionally, the coating orlayer 538 may be disposed over the entire rear surface (whereby thecoating may provide environmental protection if needed or desired at andover the metallic layer materials (such as aluminum or gold or the like)of the reflective layer or coating, or may be disposed along thedemarcation line 526 a to substantially fill in the demarcation line 526a.

The paint or coating or layer may be selected to be any desired color ortint so as to provide the desired edge demarcation of the perimeter orborder reflector region 526. For example, the coating or layer 538 maycomprise a dark color, such as black or the like, or may comprise alight grey or other color or tint, depending on the particularapplication and, more particularly, on the color or visibility orviewability of the perimeter band on the electro-optic reflectiveelement at the driver-side rearview mirror. For example, the darker thecolor of the coating or layer or paint, the more readily viewable ordiscernible the demarcation line 526 a may be to a person viewing theexterior rearview mirror. Thus, it may be desirable to provide a lightgrey (or similar or selected pale color or the like) demarcation line sothat the demarcation line is readily viewable/discernible, but notoverly apparent or dominant at the reflective element.

The viewable width of the demarcation line (the dimension across thedemarcation line when viewed at the reflective element by a personviewing the exterior rearview mirror) may be selected to provide thedesired degree of viewability or discernibility of the demarcation line,so as to give the appearance of an edge of a perimeter band or bordercoating. Optionally, for example, the demarcation line may have a widthof preferably less than approximately 350 microns (one micron beingequal to one millionth of a meter), more preferably less thanapproximately 250 microns and more preferably less than approximately175 microns. Also, for example, the demarcation line may have a width ofpreferably greater than approximately 50 microns, more preferablygreater than approximately 75 microns and more preferably greater thanapproximately 100 microns. The demarcation line through the reflectivecoating at the rear surface of the reflective element thus functions todemarcate a perimeter border or band so as to provide the appearance ofa perimeter band at the border region of the reflective element thatsubstantially optically matches the central main reflector region of thereflective element.

Although shown and described as a substantially continuous oruninterrupted demarcation line that circumscribes the perimeter regionof the reflective element substrate, the demarcation line may be formedto only partially circumscribe the perimeter region of the reflectiveelement substrate, without affecting the scope of the present invention.For example, the demarcation line may be a line segment around a portionof the perimeter region of the substrate or the demarcation line maycomprise a non-continuous or interrupted demarcation line (such as aplurality of line segments or dashes or the like) that extends partiallyor entirely around the perimeter region of the mirror substrate.

Optionally, and as shown in FIG. 16, a mirror reflective element 510′may have a mirror reflective coating or reflector 518 and a perimeter orborder reflector region 526′ and central main reflector region 524′, anda demarcation line 526 a′, such as described above. Mirror reflectiveelement 510′ includes a second demarcation line 526 b′ established orformed (such as by laser etching or the like) in and through thereflective coating 518, such as in a similar manner as described abovewith respect to demarcation line 526 a of reflective element 510. In theillustrated embodiment, the second demarcation line 526 b′ extends alongthe lower perimeter region of the mirror substrate and curves downwardto the perimeter edge of the reflective element 510′. Such a seconddemarcation line may be desirable for a passenger-side non-electro-opticmirror reflective element so that the non-electro-optic passenger-sidemirror reflective element matches or substantially matches anelectro-optic driver-side mirror reflective element, such as, forexample, the driver-side mirror reflective element supplied by GentexCorp. of Zeeland, Mich. for a model year 2006 Audi vehicle. The mirrorreflective element 510′ may be otherwise substantially similar to themirror reflective element 510 described above, such that a detaileddiscussion of the mirror reflective elements will not be repeatedherein.

Although shown and described as having the central main reflector regionand the border reflector region (as either defined by a demarcation linethrough the reflector coating or by a separate layer or coating around aperimeter region of the reflective element) at the same surface of theelectro-optic or non-electro-optic reflective element, it is envisionedthat the border reflector band may be formed or established on thesecond or rear surface of the substrate while the central or mainreflector coating may be established on the first or front surface ofthe substrate (in such an application, masking may be required to formthe coatings at one or both sides of the substrate). Alternately, andoptionally, the border reflector band may be established on the firstsurface of the substrate while the central or main reflector coating maybe established on the second surface of the substrate (in such anapplication, masking may be required to form the coatings at one or bothsides of the substrate). Optionally, the border and central reflectorcoatings may both be on the first or front surface of the reflectiveelement, depending on the particular application of the reflectiveelement and mirror assembly.

The substrate or substrates of the reflective element may comprise anytype of suitable substrate, such as a single glass substrate or thelike. For example, the substrate may comprise a glass substrate having athickness of at least about 1.6 mm, more preferably a thickness of atleast about 1.8 mm and more preferably a thickness of at least about 2mm, but could have a greater thickness or a reduced thickness withoutaffecting the scope of the present invention. The substrate may comprisea substantially flat or planar substrate or may comprise a curvedsubstrate depending on the particular application of the reflectiveelement.

Optionally, and with reference to FIGS. 17-21, a reflective elementassembly 610 for an exterior rearview mirror assembly includes a frontsubstrate 612 (FIG. 21) and a rear substrate 614 spaced from frontreflective element substrate 612, with an electro-optic medium 616(preferably an electrochromic medium) sandwiched therebetween. The frontsubstrate 612 has a transparent conductive coating or layer 618 (such asan ITO layer, such as a ½ wave ITO layer or a doped tin oxide layer or adoped zinc oxide layer or the like) disposed on its rear surface 612 a(typically referred to as the second surface of the laminate reflectiveelement assembly) and the rear substrate 614 has a third surface minorreflector 620 (FIGS. 20 and 21) coated thereon (the mirror reflector maycomprise a layer or stack of layers of metals or a metal or stack ofmetals with at least one conductive oxide layer, such as ITO, or thelike as discussed below). The third surface mirror reflector covers thecentral region or EC-active or viewing region of the front surface 614 a(typically referred to as the third surface of the reflective elementassembly) of the rear substrate 614 but does not extend or cover fullyto the perimeter edge of the substrate), and the mirror reflectorcoating 620 overlaps a tab-out or edge wraparound coating or coatings636 (that extends substantially or fully to a perimeter edge of thesubstrate, and preferably, if in a “flush” electrochromic mirror elementconstruction, wraps around the cut edge of the substrate) as discussedbelow. An epoxy seal material 622 (FIG. 21) or the like, is appliedbetween the substrates to define the cavity for the electrochromicmedium and to adhere the substrates together. The epoxy seal 622overlaps and seals an overlap region 621 where the third surface mirrorreflector 620 overlaps the wraparound coating 636 to environmentallyprotect the third surface mirror reflector 620, as also discussed below.

Because an exterior rearview mirror is located at the exterior of avehicle, the mirror reflective element is typically exposed to a hostileenvironment and may be exposed to humidity, rain, snow, ice, dirt, salt,debris and the like. In typical laminate electrochromic reflectiveelement assemblies, any portion of the mirror reflector layer or layersthat extend beyond the perimeter seal toward the outer edge of the rearsubstrate (for purposes of electrical contact) are particularlyvulnerable. Thus, it is desirable to provide a robust reflectiveelement, such as a mirror reflective element having environmentallystable coatings or layers on the surfaces of the reflective elementsubstrates that can be exposed to the hostile environment. Although suchenvironmentally stable or robust coatings, as discussed below, aredesirable and suited for exterior mirror applications, aspects of suchcoatings and the constructions herein are equally suited for interiormirror applications as well.

As shown in FIG. 18, the rear substrate 614 of reflective element 610includes a third surface conductor or coating 636 that is disposed overthe uncoated glass substrate and along a portion (such as an uncoatedperimeter region or perimeter glass surface) of the third surface 614 aof rear substrate 614. The third surface coating 636 includes a thirdsurface conductor portion or tab-out portion 636 a (disposed at theperimeter region of the third surface 614 a) and a wrap-around portionor coating 636 b that wraps around and over a perimeter edge Or cut edge614 c of rear substrate 614. Third surface coating 636 may comprise anenvironmentally stable metallic layer or material, such as chromium orrhodium or ruthenium or platinum or the like, or a stack of, forexample, of chromium/ruthenium or chromium/rhodium or chromium/platinumor the like, and thus provides an environmentally stable or robustwraparound coating at the perimeter region of the front surface 614 a ofthe rear substrate 614.

As shown in FIGS. 17 and 19, rear substrate 614 also includes a fourthsurface conductor or coating 638 disposed over the glass substrate andalong a portion (such as an uncoated perimeter region or perimeter glasssurface) of the fourth surface 614 b of rear substrate 614. Fourthsurface coating 638 includes a fourth surface conductor portion orelectrical contact portion 638 a and a wrap-around portion or coating638 b that wraps around and over perimeter edge or cut edge 614 c ofrear substrate 614 onto the cut edge of the substrate and contactingthird surface conductor coating 636 (and may be disposed at or over orunder wrap-around portion 636 b at perimeter edge 614 c, as shown inFIG. 19), in order to provide electrical conductivity between the fourthsurface conductor 638 a and the third surface conductor 636 and thethird surface mirror reflector coating 620, as discussed below. Thefourth surface conductor 638 a and wrap-around coating 638 b maycomprise the same material as the third surface conductor 636 a andwrap-around coating 636 b (such as chromium or molybdenum or tungsten orHastelloy or ruthenium or rhodium or platinum, or a stack of, forexample, of chromium/ruthenium or chromium/rhodium or chromium/platinumor the like, or other suitable environmentally stable conductivematerial). Alternately, the fourth surface coating 638 may comprise adifferent material than the third surface coating 636, with bothcoatings or layers being selected to be substantially environmentallystable or robust.

The third and fourth surface conductors 636, 638 may be disposed ontothe respective perimeter regions and edge of the rear substrate duringthe same or separate coating processes. For example, the rear substratepreferably has at least the third and fourth perimeter edge wraparoundenvironmentally robust conductor coatings formed in a dual-sidesputtering coating chamber (such as a sputter-up/sputter-down or asputter-left/sputter-right coating chamber where the substrate carrierpasses through opposing sputter targets so that the substrate can becoated at both sides), such as by utilizing aspects of the coatingchambers and processes described in U.S. patent application Ser. No.11/021,065, filed Dec. 23, 2004, now U.S. Pat. No. 7,255,451, which ishereby incorporated herein by reference in its entirety. In such achamber, for example, one of the conductors (such as, for example,fourth surface conductor 638) may be sputter coated from the bottom ofthe substrate, while the other conductor (such as, for example, thirdsurface conductor 636) may be sputter coated from the top of thesubstrate (with the central region of the respective third and fourthsurface (and other perimeter portions or regions where the conductorcoating is not desired) masked so that the respective conductingcoatings are deposited only at an edge). The conductor coatings 636, 638thus are disposed over the perimeter edge 614 c and over a perimeterregion of the respective glass surfaces 614 a, 614 b of the rearsubstrate 614. Optionally, one or both of the conductor coatings 636,638 may be disposed around more than one perimeter region or aroundsubstantially the entire perimeter of the substrate. Optionally, one ofthe coatings may be disposed over the other coating at the perimeteredge 614 c (if the coatings are disposed during separate coatingprocesses) or the coatings may be disposed together onto the perimeteredge (such as for applications where the coatings are disposed during asingle coating process) so as to contact one another and establishelectrical conductivity between the conductor coatings 636, 638 and,thus, between the fourth surface and the third surface of the rearsubstrate of the reflective element assembly.

After the conductor coatings 636, 638 are disposed at the respectiveperimeter regions and at the edge of the substrate, the perimeterregions 614 d of the front surface 614 a of rear substrate 614 may bemasked, whereby the third surface mirror reflector coating or layer 620is disposed (such as via a sputter deposition process or the like) overthe unmasked or central portion or EC-active portion or viewing portionor region (which is within the perimeter seal of the reflective elementassembly when the reflective element assembly or cell is assembled) ofthe third surface 614 a, and within or encompassed or surrounded by theperimeter band or region 614 d of the third surface 614 a of rearsubstrate 614. The third surface perimeter band 614 d may be establishedby masking the perimeter region of the third surface 614 a prior todeposition of the mirror reflector coating or layer 620 onto the centralregion of the third surface 614 a. The third surface mirror reflectorcoating or layer 620 may comprise a transflective coating or layer orother suitable third surface mirror reflector coating comprisingreflective and conductive coatings. For example, the third surfacemirror reflector coating 620 may comprise a reflective metallic coatingor layer or multiple coatings or layers, such as a bi-layer or the like,such as a reflective metallic coating or layer (or multiple coatings orlayers), such as a layer of chromium/rhodium or chromium/ruthenium ormolybdenum/chromium, or an ITO/silver/ITO or AZO/silver/AZO stack oflayers or the like, over the central region or viewing region orBC-active region of the front surface 614 a of the rear substrate 614.

Optionally, the third surface mirror reflector coating may not betransflective (such as for a fourth surface reflective element), and/ormay comprise a substantially non-transmissive metallic reflectorcoating, such as a coating or layer of silver or aluminum or theiralloys or the like, or may comprise a substantially non-transmissiveITO/Ag/ITO or AZO/Ag/AZO coating or layers or the like. Optionally, therear substrate may initially be coated with a transparent conductivecoating, such as ITO or the like, disposed over its entire third orfront surface (for example, a substrate having such a coating alreadyestablished thereon may be purchased by the mirror manufacturer),whereby the third surface conductor 636 is disposed over the perimeterregion of the ITO coated third surface and the mirror reflector coatingor coatings is/are disposed over the ITO coated central region orEC-active region of the rear substrate, without affecting the scope ofthe present invention.

As shown in FIGS. 20 and 21, the mirror reflector coating or layer 620is disposed over the central region or portion of the third surface 614a that is substantially surrounded by the perimeter seal 622 and so isenvironmentally protected thereby. The mirror reflector coating 620overlaps and makes conductive contact at a portion of the third surfaceconductor 636 a of third surface coating 636, such as at overlap region621, so as to contact the conductor 636 a and establish conductivitybetween the mirror reflector coating 620 and the third surface conductorcoating 636 and, thus, between the mirror reflector coating 620 and thefourth surface conductor 638 a at the fourth surface 614 b of rearsubstrate 614. As can be seen in FIG. 21, the overlap region 621 ispositioned inward of the perimeter edge of the rear substrate and at aregion that is encompassed by the perimeter seal 622 when the seal 622is established at the rear substrate 614. Perimeter seal 622 thusoverlaps a portion of the mirror reflector coating 620 and a portion ofthe third surface conductor 636 a and limits or substantially precludesexposure of the mirror reflector coating 620 to the exterior elements.The perimeter seal overlaps and seals against a perimeter portion of themirror reflector coating and the uncoated glass surface of the thirdsurface of the rear substrate in other perimeter regions where the thirdsurface conductor 636 a is not established.

The fragile or less environmentally stable mirror reflector coating 620thus terminates or stops within the area encompassed by the perimeterseal 622 and the robust or more environmentally stable third surfaceconductor coating 636 a contacts/overlaps the fragile mirror reflectorcoating 620 in the area encompassed by the perimeter seal. Thus, themore environmentally stable third surface conductor coating 636 aextends outward from the perimeter seal and over the third surface atthe perimeter region and to the edge of the substrate. The perimeterseal 622 thus provides environmental protection for the mirror reflectorcoating 620, so that the mirror reflector coating 620 may comprise aless environmentally stable or robust material, such as silver or silveralloy or ISI stack (such as metal oxide/metal/metal oxide stack, such asan ITO-silver-ITO stack or a ZnAlO/Ag/ZnAlO stack or a ZnAlO/Al/ZnAlOstack or a ITO/Ag/ZnAlO stack or the like), while the third surfaceconductor coating 636 and the fourth surface conductor coating 638 maycomprise a more environmentally stable or robust material (such aschromium or rhodium or ruthenium or the like). Thus, the exposedconductor coatings 636, 638 (i.e., the coatings that are not encompassedand sealed by the perimeter seal and thus not within the sealed ECregion of the reflective element) may be exposed to the elements and maywithstand exposure to the elements at the exterior perimeter of the rearsubstrate and/or reflective element.

In the illustrated embodiment, and as also shown in FIG. 21, electricalconnectors 640 a, 640 b, such as terminals or clips or pins orconductive epoxy or paste or the like, may be conductively connected tothe second surface transparent conductive coating 618 and the fourthsurface conductor 638 a, respectively. The connectors 640 a, 640 b maybe connected to an electrical wire or wire harness or lead or terminalor the like (not shown) to electrically connect the electrochromicreflective element to a vehicle or mirror control or power source or thelike. Thus, the environmentally stable conductive wrap-around coatings636, 638 provide electrical conductivity between the fourth surface ofthe reflective element to the third surface mirror reflector coating 620at the EC-active region of the third surface of the reflective element,while the third surface mirror reflector coating 620 is substantiallysealed and protected and substantially or entirely not exposed to theelements.

In a preferred embodiment, the rear substrate 614 may comprise a glasssubstrate having a thickness of between about 1.1 mm and about 1.6 mm orthereabouts. The third surface conduct coating 636 may comprise a layerof chromium, such as a layer of chromium that is sputtered depositedonto the glass substrate to a thickness of about 800 to about 1000angstroms or more. The fourth surface conductor coating 638 may comprisea layer of chromium, such as a layer of chromium that is sputtereddeposited onto the substrate to a thickness of about 800 to about 1000angstroms, and the coating may be overcoated with a layer of ruthenium(such as a layer that is about 300 angstroms thick) or a layer ofrhodium (such as a layer that is about 200 angstroms thick), whereby theelectrical connector (typically a silver paste or epoxy or the like)contacts the overcoated layer of ruthenium or rhodium to establish theelectrical connection to the conductor coating/coatings.

Optionally, and as shown in FIG. 21, reflective element 610 may includea display device 630 at the fourth surface 614 b of rear substrate 614.Display device 630 may be operable to emit or project illuminationthrough the reflective element 610, such as through a window establishedat the third surface mirror reflector coating 620, or through the thirdsurface mirror reflector coating 620 for a transflective reflectiveelement. Display device 630 may be operable to provide a turn signalindicator or a blindspot alert indicator or the like, and may bedirected to be substantially viewable to a driver of a rearwardlyapproaching vehicle or to be substantially viewable to the driver of thesubject vehicle, depending on the particular application of the displaydevice. The display device and reflective element may utilize aspects ofthe display devices described in U.S. patent application Ser. No.11/226,628, filed Sep. 14, 2005 (Attorney Docket DON01 P-1236); and/orU.S. provisional applications Ser. No. 60/717,093, filed Sep. 14, 2005by Lynam; Ser. No. 60/732,245, filed Nov. 1, 2005; and/or Ser. No.60/759,992, filed Jan. 18, 2006, which are hereby incorporated herein byreference in their entireties.

The construction shown in FIG. 21 particularly suits “flush” typereflective elements having overhang regions (defined by the frontsubstrate being larger than the rear substrate so as to provide anoverhang region or regions along the upper and/or lower perimeterregions of the reflective element assembly) as shown in FIG. 21 (andsuch as described in U.S. patent application Ser. No. 11/226,628, filedSep. 14, 2005 (Attorney Docket DON01 P-1236), which is herebyincorporated herein by reference in its entirety). However, for offsetreflective elements, where the front and rear substrates may besimilarly sized, but one is vertically offset relative to the other(such as described in U.S. patent application Ser. No. 11/021,065, filedDec. 23, 2004, now U.S. Pat. No. 7,255,451; and/or U.S. Pat. Nos.5,724,187 and 5,668,663, which are hereby incorporated herein byreference in their entireties), the reflective element may not include afourth surface conductive wraparound coating or bus bar. For example, anoffset reflective element may not include a fourth surface conductorcoating, whereby the environmentally stable third surface conductorcoating may be disposed at the perimeter region of the front or thirdsurface of the rear substrate and may or may not wrap-around onto thecut edge of the rear substrate, whereby the electrical connection to thethird surface coatings may be made by a known clip or the like at theperimeter region so as to contact the conductor coating at the perimeterregion of the third surface of the rear substrate.

The third surface mirror reflector coating (established over the centralor EC-active region of the glass third surface of the rear substrate)may comprise a metallic coating or layer or a metal oxide/metal/metaloxide coating, such as a stack of materials or layers, such as, forexample, a layer of ITO (such as about 500 angstroms thick), a layer ofmetal (such as a layer of silver or aluminum that is about 300 angstromsthick), and a layer of ITO (such as about 120 angstroms thick).Optionally, the third surface mirror reflector stack may comprise analuminum zinc oxide (AZO) stack, such as a stack comprising an AZOlayer, a metallic layer, and another AZO layer (for example, anAZO/Ag/AZO stack of layers). The layer or layers of AZO may be sputteredfrom a sputtering target comprising zinc oxide doped with aluminumoxide. For example, a doped zinc oxide target having ZnO: 2% Al₂O₃ hasachieved desired results. Such an AZO layer may be formed via sputterdeposition with such a doped zinc oxide sputtering target, such as canbe made by a co-precipitation process; formed of ZnO: 2% Al₂O₃. Notethat while good results have been obtained with aluminum-doped zincoxide, other dopants such as silver or gold can be used.

Preferably, the sputtering is done by direct current (DC) sputtering,more preferably by pulsed DC sputtering, and more preferably by mediumfrequency (such as within a range of about 40 kHz to about 1 MHz orthereabouts) dual magnetron DC sputtering. Alternatively, radiofrequency (RF) sputtering could be used or other sputtering techniquesor systems may be used, depending on what is better suited for theparticular chamber and chamber conditions.

Advantages found by utilizing an AZO layer or layers include that it isa lower cost material than ITO. We find that effective AZO coatings forpurposes of the present invention (i.e. highly transmissive andsufficiently conductive to allow electron flow therethrough forelectrical contact to the electrochromic medium when a thin layer of AZOis overcoated over the underlying metal layer (the layer of AZO thatcontacts the electrochromic medium when the reflective element isassembled)) can be formed or established using non-reactive DC magnetronsputtering (and hence obviating the cost/complexity of introducing andcontrolling an oxygen partial vapor pressure during the sputterdeposition process). Although the AZO layer may not be as conductive asan ITO layer, the conductivity of the AZO layer is sufficient to allowthe electron flow from the highly conductive metallic layer (thatunderlies the AZO layer and acts as a conductive raceway over the thirdsurface of the rear substrate) and through the thin AZO layer toenergize the electrochromic medium when electrical power is applied tothe connectors or contacts of the reflective element assembly. Forinstance, and for the AZO layer that the electrochromic medium contacts,we find that AZO layers having a sheet resistance of greater than about100 ohms per square, or in certain constructions greater than about 250ohms per square, are effective.

The glass surface of the rear substrate thus may be coated with a thirdsurface mirror reflector comprising a conductive coating or a stack ofcoatings or layers. For example, the glass surface may be regionallycoated (such as at a perimeter region) with a conductive tab-out layerof sputtered chromium (such as a layer having a thickness of about 500angstroms or thereabouts), and the central or EC-active or viewingportion of the front surface of the substrate, and a portion of theconductive tab-out layer, is overcoated with a third surface mirrorreflector/mirror transflector layer. For example, a mirror reflectorcoating may be disposed that comprises a stack of layers, such as, forexample, an AZO layer (such as about 500 angstroms thick), a metalliclayer (such as a highly conducting layer of silver or aluminum dopedsilver or doped aluminum or the like and having a thickness of about 800angstroms to about 1000 angstroms or thereabouts), and a layer ofaluminum zinc oxide or AZO (such as a layer of AZO having a thickness ofabout 100 angstroms to about 200 angstroms or thereabouts). Such anAZO:metal:AZO stack of layers thus provides the desired transmissivityand reflectivity at the EC-active region of the reflective element,while being sufficiently conductive for its intended purpose ofselectively energizing the electrochromic medium. Other thicknesses oflayers and other materials may be utilized depending on the particularapplication and desired characteristics of the reflective element andmirror assembly.

Optionally, and desirably, a rear substrate for a reflective element mayhave a mirror reflector coating that utilizes chromium (or titanium orother stable metal) for an adhesion layer at the glass surface of thefront of the substrate. For example, a preferred embodiment of such arear substrate may have a mirror reflector coating comprising a layer ofchromium (such as a layer that is about 400 angstroms thick), with alayer of metal, such as silver or aluminum or alloys thereof the like,such as a layer of silver that is about 800 angstroms thick, disposedthereon. A layer of AZO (such as a layer of AZO that is about 150angstroms thick) is then non-reactively deposited or disposed onto themetal layer. Thus, the AZO layer or overcoat (that contacts theelectrochromic medium when the reflective element is assembled andprotects or isolates the metal layer from the electrochromic medium) maybe non-reactively deposited, and thus obviating the cost/complexity ofintroducing and controlling an oxygen partial vapor pressure during thesputter deposition process. Such a mirror reflector coating may bedisposed at the glass third surface of the rear substrate via a multipletarget sputtering process. The adhesion layer of chromium at the glasssurface of such a rear substrate may also provide reduced costs of themirror reflector coating and of the reflective element as compared torear substrates with an ITO adhesion layer at the glass surface.

Note that a benefit of a third surface reflector that comprises a glasssubstrate coated first with an environmentally stable electricallyconducting layer (such as chromium), which in turn is overcoated with ahighly reflecting metallic mirror layer (such as a layer of silver or ofa predominantly silver silver-alloy or such as a layer of aluminum or ofa predominantly aluminum aluminum-alloy), which in turn is overcoatedwith a transparent electrically conductive layer (that is disposedbetween the highly reflecting mirror metallic layer and theelectrochromic medium within the electrochromic mirror element cell), isthat electrical conductivity and contact to the electrochromic mediumcan be sustained by the underlying environmentally stable electricallyconducting layer even if its overlaying environmentally fragile layers(such as silver or the like) degrade or deteriorate due to environmentalexposure. An example of such a third surface reflector comprises aglass/chromium/metal (such as silver or aluminum or an alloy of silveror of aluminum)/aluminum doped zinc oxide [herein referred to as “CAZ”].In such an exemplary construction, the third surface reflector coating(TSR) can be taken out to the edge (or wrap-around the edge) of thesubstrate beyond the seal, and the end product can be environmentallyresilient without the need to use encapsulants or the like toenvironmentally protect tab out regions; cut-edge wraparound coatings,offset regions, overhang regions and/or the like. This is because theelectrical continuity of CAZ or similar constructions is environmentallystable due to the underlying bedrock of the environmentally stablemetallic electrical conductor, such as chromium. In such constructions,any environmentally fragile layers, such as AZO and silver coatingportion, that extends beyond the perimeter seal of the mirror cell maybe exposed to environmental conditions and so may deteriorate in severeenvironmental testing, such as 85C/85% RH, salt spray, steam autoclave,etc. (or in field usage on a vehicle), while the underlying adhesionlayer/base electrically conducting coating of chromium remains intact.Thus, the EC mirror element cell can still be powered even if theoverlying layers of the CAZ were partially or substantially deterioratedat the likes of a tabout or edge wraparound or offset or overhangregion. Thus, for example, in an offset interior mirror (or exteriormirror) electrochromic cell construction, the clips or contacts canmaintain electrical contact to the chromium (and hence thereby to thethird surface mirror reflector coating that is protected by the ECperimeter seal itself), even if the overlying silver or AZO layer maylocally corrode.

In a flush construction, where the likes of an edge overcoat or fourthsurface electrical connection, such as via a conductive epoxy or thelike, may be made, the conductive epoxy itself may locally encapsulateand environmentally protect the CAZ layer or stack, but having thebedrock of environmentally stable chromium (or a similar environmentallystable metal electrically conducting thin film layer such as of achromium-based alloy or such as of as a nickel-based alloy, such as anInconel or a Hastelloy, or such as of an iron-based alloy, such as astainless steel or such as of titanium or a titanium-based alloy) hasthe advantage that the underlying chromium or similarly environmentallystable metal thin film layer remains electrically conducting andintegral even should the overlying silver or AZO (or other transparentelectrical conductor, such as other doped zinc oxides or a doped indiumtin oxide, such as ITO or indium oxide or tin oxide or doped tin oxide)degrade or deteriorate in harsh environmental conditions. For example,for third surface mirror reflectors, such as ITO/Ag/ITO (ISI) or thelike, where the silver metal layer is environmentally vulnerable, anencapsulating or potting material (such as described in U.S. patentapplication Ser. No. 11/021,065, filed Dec. 23, 2004, now U.S. Pat. No.7,255,451, which is hereby incorporated herein by reference in itsentirety) may be used at the tabout or edge wraparound or offset oroverhang regions, and this has proven to be successful. But, with thelikes of CAZ, where the underlying bedrock adhesion-enhancing andelectrically-conducting metal layer comprises an environmentally stablemetal material, such as chromium or titanium or nickel or metal alloysor the like, the use of any extra potting or encapsulating material,such as at a tab-out region or at a clip region or wherever electricalconnection is being made to the third surface reflector coating or layeroutside of its sealed portion, becomes optional.

An example of a preferred stack design for an interior rearview mirrorreflective element 710 is shown in FIG. 22 and includes a rear glasssubstrate 714 (such as float glass) and a CAZ layer 720 disposed at thefront or third surface of the rear substrate 714. The CAZ layer 720comprises a layer of chromium 720 a (having a thickness of about 800angstroms) disposed on the front surface of the rear substrate (i.e. thethird surface of the electro chromic cell), a layer of silver 720 b(having a thickness of about 800 angstroms) over the chromium layer 720a, and a layer 720 c of ZnO:Al (such as a layer deposited by sputteringfrom a sputter target of ZnO:Al₂O₃ so as to have a layer thickness ofabout 80 angstroms) disposed over the silver layer 720 b. Anelectrochromic medium 716, such as an electrochromic solid polymermatrix (SPM) or other suitable electrochromic medium (such as a liquidor solid electrochromic medium), is disposed between the coated rearsubstrate 714 and a coated front substrate 712 (such as in a 110 μminterpane gap between the substrates and coatings/layers) and sealedwithin the interpane cavity via a perimeter seal 722 (such as an epoxyseal). The front glass substrate 712 (preferably float glass) has alayer of a transparent electrical conductor 718 (such as ITO, andpreferably having a resistivity of about 12 ohms per square) disposed onits rear or second surface. Optionally, and as shown in FIG. 22, thereflective element 710 may include an indicia coating or layer orelement 724, which preferably is disposed at the second surface of thefront substrate (as shown in FIG. 22), but may be optionally disposed atthe third or fourth surface of the rear substrate, such as in themanners described herein. Of course, the FIG. 22 is purely exemplary,and other constructions and materials and thicknesses may be selectedand implemented depending on the particular application and desiredperformance of the interior or exterior vehicular mirror reflectivecell, while remaining within the spirit and scope of the presentinvention.

The CAZ layers may be coated on either the tin side of the float glasssubstrate or the air side of the float glass substrate. Otherenvironmentally stable electrically conductive materials, such as alayer of titanium or the like, may be disposed at the substrate in placeof the layer of chromium. For example, a grade 2 titanium may be used.Although AZO is typically about ⅓ the cost of ITO and thus may bedesired, ITO or other transparent conductors can be used. Alternately,however, AZO or other suitable or similar transparent conductors can beused instead of the ITO. Alternately, aluminum, such as Al(6061), or analuminum alloy or a silver alloy, which has a high reflectivity of lightincident thereon, such as a reflectivity of at least about 80 percent oflight incident thereon, more preferably at least about 85 percentreflective of light incident thereon, and more preferably at least about90 percent reflective of light incident thereon, may be used instead ofsilver.

Preferably, the surface or surfaces of the glass substrates are cleanedand/or treated prior to deposition of the coatings. For example, thesurface may be prepared or treated to prepare the surface and/or todissolve any moisture or water vapor from the surface. For example, thesubstrate may be heated prior to deposition or the surface may betreated with a plasma or ion beam, such as described in U.S. patentapplication Ser. No. 11/021,065, filed Dec. 23, 2004, now U.S. Pat. No.7,255,451, which is hereby incorporated herein by reference in itsentirety.

Preferably, the coatings or layers are deposited at the substrate in amulti-cathode (either vertical or horizontal) conveyorized sputterchamber. The chamber may contain an argon atmosphere at the AZO and/orother sputtering target, such as of silver or chromium, at about 3-5mtorr, and the AZO material may be sputtered at about 300 sccm or moreof argon flow. However, other chambers and/or processes may beimplemented, depending on the particular coater being used and dependingon the particular application. The power density applied to the AZOtarget (and to other targets) is preferably at least about 3 W/cm², morepreferably at least about 5 W/cm², and more preferably at least about 8W/cm². Due to the relatively inferior electrical specific conductivityof AZO, a dual magnetron sputtering system is desired for long termstable, arc-free operation within the sputter chamber. An example of asuitable AZO sputtering target is a ceramic of ZnO:Al₂O₃ (e.g., 98%/2%weight), formed from a co-precipitation process, “hip'd” and sintered.The preferred density is greater than about 5.3 g/cc. The AZO tiles maybe attached, such as soldered, such as indium soldered, to an OFHCcopper backing plate.

One desirable property of AZO is that it can be deposited in ametallizer sputter chamber without the cost/complexity of introducingoxygen gas handling to the vacuum chamber at the sputter station for theAZO. Thus, advantageously, a chromium target and a silver target and anAZO target (in that sequence relative to the direction of travel of thesubstrates thereunder) may be disposed in the same vacuum chamber andmay be commonly exposed to the same sputtering atmosphere, such as theargon atmosphere described above. Thus, the sputtering station and thesputtering of the thin films may be achieved non-reactively and withoutrecourse to introducing additional oxygen. By contrast, but optionally,another transparent conductor, such as ITO, could be used instead ofAZO. However, reactive sputtering in a oxygen rich atmosphere isdesirable for ITO transparent electrical conductor thin film deposition,and in such a vacuum chamber, steps must be taken to isolate thenon-reactive sputtering of the preceding silver and chromium metalliclayers from the reactive sputtering of the ITO layer. We findsurprisingly good results when AZO is used in the CAZ layer and when theAZO is deposited in an argon sputtering atmosphere.

Optical properties of both the coated rear substrate and of thecompleted CAZ interior EC mirror element are shown in FIGS. 23 and 24,respectively. FIG. 23 shows the reflectance of the stack 720 of FIG. 22of light incident on the coated rear substrate 714. As shown, thereflectance of visible light incident on the coated rear substrate 714is about 90 percent or more. When the coated substrate 714 is formedinto a cell 710, such as a cell using an electrochromic solid polymermatrix (SPM) (such as described in U.S. Pat. Nos. 5,725,809; 5,910,854;6,002,511; 6,154,306; 6,245,262; 6,420,036; 6,855,431; and 6,954,300,which are hereby incorporated herein by reference in their entireties),the reflectance of light incident on the cell is as shown in FIG. 24.FIG. 24 shows the reflectance of light incident on the cell when thecell is in its bleached and when the cell is in its darkened or coloredstate (such as with about 1.2 volts applied across the cell). As can beseen in FIG. 24, visible light reflectance is greater than about 80percent or thereabouts in the bleached state and around 10 percent orthereabouts in the colored state.

The optical constants of the ZnO:Al layer are shown in FIG. 25. Morespecifically, FIG. 25 shows the optical constants, particularly theindex of refraction “n” and the extinction coefficient “k”, for thecoated substrate. The sheet resistance of the coated rear substrate andof its individual layers was measured to be about 4-5 ohms per squarefor the 800 angstroms thick chromium layer and less than about 1 ohm persquare for the 800 angstroms thick silver layer.

The electrochromic performance (high end/low end reflectivity and colorand bleach speeds, etc.) of the CAZ interior EC mirror element is shownin the tables of FIGS. 26 and 27. The tables show the rate tocolor/bleach of the cells and the maximum and minimum percentreflectance of light incident thereon, and the maximum current draw andsteady state current draws of the cells. FIG. 26 shows the initialperformance characteristics of various samples at about 23 degreesCelsius and at 1.2 volts when powered, while FIG. 27 shows the finalperformance characteristics of various samples at the same temperatureand voltage, but after the samples have endured about 50,000 cycles at65 degrees Celsius and 95 percent relative humidity.

The AZO is desirably deposited in an argon sputter atmosphere andwithout added oxygen in the sputtering gas mix or composition. This maysimplify in-line sputter coater designs, since there may be no need for“process isolation” between the chromium sputtering station/cathode, thesilver sputtering station/cathode and the AZO sputteringstation/cathode.

We find that the optical extinction coefficient “k” of ITO depositedunder nearly identical oxygen-free sputtering in argon conditions isover ten times greater than that for AZO that is similarlynon-reactively sputtered. Also, ITO exhibits an index grading, whereasAZO does not. We also find reduced formation of surface nodules usingthe AZO ceramic target when it is non-reactively sputtered as comparedto reactive sputtering with ITO targets. Further, AZO sputtered in pureargon has a faster deposition rate than ITO in Ar/O₂; such as at leastabout 30 percent faster rate.

If a display on demand transflective display application is desired, thestack or layers used for the third surface reflector are correspondinglyreduced and/or adjusted in thickness. For enhanced transmissivity, atransparent conductor may be used as the adhesion layer in place of thechromium. For example, a transflective TSR rear substrate may comprise;glass/AZO/Ag/AZO or glass/ITO/AZO/Ag/AZO. Due to the K value of AZO, itsuse in transflective third surface reflector (TSR) constructions can bedesirable, given that such a DOD stack has a good T %, R % and neutralappearance.

A chromium layer has excellent adhesion to an ITO base coat and mayimprove the environmental robustness of the cell and may eliminate anyneed for surface preparation, such as ion beam cleaning.

AZO exhibits less compressive stress compared to ITO, which may enablemore environmentally stable DOD stacks with thicker AZO layers.

AZO also may be used as the second surface transparent conductivecoating or oxide (TCO) in the electrochromic cell if sufficiently thickso as to have a sheet resistance of at or about 20 ohms per square orlower. AZO is less inherently conductive than ITO, which has a specificresistivity of about 2×10-4 ohm.cm. With appropriate depositionconditions, including use of an oxygen sputtering atmosphere and heatedsubstrate, a specific resistivity of about 6×10-4 ohm.cm or better ofAZO can be achieved. The AZO layer, when deposited on the glasssubstrate, may provide a transparent conductor having a sheet resistanceof about 20 ohms per square or lower if appropriately deposited. Anelectrochromic cell thus may be constructed using AZO as its secondsurface transparent electrically conductive layer.

Therefore, the present invention provides an electrochromic mirrorelement with the rear glass substrate third surface reflector (TSR)coated with an environmentally stable or resilient electricallyconductive metal layer, such as chromium or titanium, and with a highlyspecularly reflective metal layer [such as comprising silver or silveralloy (such as preferably at least 80 percent and more preferably atleast 90 percent silver content) or aluminum or aluminum alloy (such aspreferably at least 80 percent and more preferably at least 90 percentaluminum content) or the like] disposed over the environmentally stableunderlying layer. The highly reflecting mirror reflective layer itselfthus has a reflectivity of preferably at least about 80 percentreflectivity (more preferably at least about 85 percent reflectivity,and more preferably at least about 90 percent reflectivity) of lightincident thereon, as measured per SAE 3964a. The AZO layer or othertransparent electrically conductive layer is then disposed over thehighly reflecting mirror reflective metal layer and need only have amodest but finite electrical conductivity, since the underlying highlyreflecting mirror reflective layer and/or the adhesion promotingenvironmentally stable metal layer can provide the desired highelectrical conductivity across the third surface of the EC cell. The CAZor similarly coated rear substrate thus provides substantialreflectivity at the third surface of the mirror element, while providingan environmentally stable layer for providing conductive continuity tothe third surface of the mirror element and any portions of the thirdsurface reflector such as tabouts or edge wraparounds or offset regionsor overhang regions or the like.

Optionally, and as shown in FIG. 28, an electro-optic mirror assembly710′ (such as for an interior or exterior mirror assembly) includes arear glass substrate 714′ and a larger front substrate 712′ so that nocross dimension of the smaller rear substrate 714′ extends beyond acorresponding cross dimension of the larger front substrate 712′. Anelectrochromic medium 716′, such as an electrochromic solid polymermatrix (SPM) or other suitable electrochromic medium (such as a liquidor solid electrochromic medium), is disposed between the coated rearsubstrate 714′ and a coated front substrate 712′ (such as in a 110 μminterpane gap between the substrates and coatings/layers) and sealedwithin the interpane cavity via a perimeter seal 722′ (such as an epoxyseal). Of course other thicknesses or interpane gaps can be used withoutaffecting the scope of the present invention.

Rear substrate 714′ includes a third surface mirror reflector 720′(optionally, the third surface mirror reflector may be a third surfacetransflective mirror reflector) disposed at the front or third surface714 a′ of the rear substrate 714′. The third surface mirror reflector720′ may be any type of suitable third surface mirror reflector, such asa third surface mirror reflector similar to the CAZ reflector describedabove, or a third surface reflective element consisting ofglass/chromium/ruthenium or glass/ITO/silver or silver alloy/ITO or thelike. For example, the third surface mirror reflector 710′ may include alayer 720 a′ of environmentally stable metallic material, such aschromium or the like, disposed on the front surface of the rearsubstrate (i.e. the third surface of the electrochromic cell), and alayer or layers 720 b′ of metal/transparent conductivematerial/materials over the chromium layer 720 a′, such as describedabove. The third surface mirror reflector 720′ includes a wraparoundportion or tabout portion 721′ that wraps around and overcoats aperimeter edge 714 c′ of the rear substrate 714′ in order to facilitateelectrical connection at the fourth surface as discussed below.

As can be seen in FIG. 28, a portion of the third surface mirrorreflector 720′ terminates at the third surface 714 a′ of the rearsubstrate 714′ before the perimeter edge 714 d′ and within the sealregion so that there is a gap 714 e′ at the third surface between theperimeter edge region 714 d′ and the edge of the third surface mirrorreflector 720′. For example, the third surface of the rear substrate maybe masked at a portion or region along the perimeter edge 714 d′ of thesubstrate during the coating or deposition of the third surface mirrorreflector 720′ so that a portion 714 e′ of the third surface 714 a′ isdevoid of the third surface mirror reflector. The masked portion or gapportion 714 e′ may be only a portion or section or length along theperimeter edge 714 d′, and provides electrical isolation between thethird surface mirror reflector and a conductive material or element 719′that provides electrical conductivity between a rear or fourth surfacecontact 740 b′ and the second surface transparent conductor 718′, asdiscussed below. The third surface mirror reflector may be disposed overthe rest of the third surface 714 a′ except at the gap portion, leavingan area (such as about 1 to 2 cm long along the edge 714 d′) along theedge region 714 d′ that is devoid of the third surface mirror reflector.

The gap portion 714 e′ electrically isolates or insulates the thirdsurface mirror reflector 720′ from the outer perimeter region or edge714 d′ of rear substrate 714′ at the region or portion along theperimeter edge at which the gap portion is established. The perimeterseal 722′ is disposed at and substantially fills in the gap portion 714e′ to further electrically isolate or insulate the third surface mirrorreflector 720′ from the outer perimeter region or edge 714 d′ of rearsubstrate 714′ and to obviate any electrical contact or shorting withthe second surface conductive electrode. The gap 714 e′ may be formed orestablished by masking of the perimeter edge region 714 d′ during thecoating/deposition process of the third surface mirror reflector 720′,or the third surface mirror reflector may be disposed over substantiallythe entire third surface and the third surface mirror reflector may beremoved at the gap region via deletion or ablation (or sand blasting orother suitable deletion/ablation means, such as laser ablation) of thethird surface mirror reflector 720′ at or near the perimeter edge region714 d′, without affecting the scope of the present invention.

The front glass substrate 712′ has a transparent electrical conductor718′ disposed on its rear or second surface 712 a′. As shown in FIG. 28,a perimeter band 726′ (which may comprise any suitable material, andpreferably is a reflective perimeter band comprising a chromiumreflective layer or the like) is disposed around the perimeter region ofthe rear surface of the front substrate 712′, with the transparentelectrical conductor 718′ overlapping the perimeter band 726′. However,the transparent electrical conductor may be disposed over the rearsurface of the front substrate and the perimeter band 726′ may bedisposed over the transparent electrical conductor, without affectingthe scope of the present invention.

Reflective element 710′ provides fourth surface electrical contacts orconnectors 740 a′, 740 b′ (such as conductive epoxy or the like) at therear surface 714 b′ of the rear substrate 714′ for electrical connectionto the third surface mirror reflector 720′ and second surfacetransparent conductor 718′, respectively, Reflective element 710′includes a fourth surface wraparound coating or coatings or layers 738′that is/are disposed over a portion of the rear surface 714 b′ of roarsubstrate 714′ and that overlaps the wraparound portion 721′ of thethird surface mirror reflector 720′. In the illustrated embodiment, thefourth surface wraparound layer 738′ comprises an environmentally stablestack of metallic conductive layers, such as a chromium layer 738 a′ anda ruthenium layer 738 b′ disposed over chromium layer 738 a′. Thewraparound portion 721′ may extend over substantially the entire edgeportion 714 c′ of the rear substrate 714′ or may extend only partiallyover the edge portion 714 c′ (such as shown in FIG. 28), with the fourthsurface wraparound portion 738′ extending partially or entirely over thewraparound portion 721′ so as to establish electrical conductivitybetween the wraparound portions 721′ and 738′. The fourth surfacewraparound coating 738′ thus provides electrical conductivity betweenthe fourth surface busbar or contact 740 a′ (such as conductive epoxy orthe like disposed at the fourth surface of the reflective element and ata portion of the wraparound coating 738′ at the fourth surface of thereflective element) and the third surface mirror reflector 720′ via thesubstantial overlap at the perimeter edge region of the rear substrate714′.

The electrical conductivity between the electrical contact 740 b′ at thefourth surface of the reflective element 710′ and the second surfacetransparent conductor 718′ may be established via a conductive elementor material 719′ (such as a conductive epoxy) disposed over a portion ofthe fourth surface 714 b′ and over the perimeter edge 714 d′ of the rearsubstrate and between the front and rear substrates so as to contact andestablish electrical conductivity to the second surface transparentconductor 718′ at the rear of the front substrate 712′. The conductiveelement or material 719′ is disposed at the reflective element at thearea or region that corresponds to the gap portion 714 e′ at which thethird surface 714 a′ is devoid of the third surface mirror reflectormaterial. Because the third surface mirror reflector 720′ is not presentat the gap portion 714 e′ at the third surface 714 a′ of the rearsubstrate (and the third surface mirror reflector terminates inboard orperimetally inward of the perimeter edge 714 d′ at the gap region 714 e′and is within the seal region of the reflective element or cell at thegap region 7144 the third surface mirror reflector 720′ is substantiallyelectrically insulated or isolated from the conductive epoxy 719′ at theperimeter edge 714 d′. The conductive element or material 719′ is thusdisposed at the portion or region of the reflective element thatcorresponds to the gap portion 714 e′ to provide electrical conductivitybetween the fourth surface contact 740 b′ and the second surfacetransparent conductor 718′ at that portion, which may be about 1 to 2 cm(or thereabouts or more or less) along the perimeter edge regions of thesubstrates of the reflective element.

Optionally, and as shown in FIGS. 29 and 30, a reflective elementassembly 810 (such as for an interior or exterior mirror assembly)includes a smaller front substrate 812 and a larger rear substrate 814,so that all overhang region 815 is defined or established by theperimeter region or regions of the rear substrate overhanging orextending beyond the perimeter region or regions of the front substrate812. Similar to rear substrate 714′, discussed above, rear substrate 814include a third surface mirror reflector 820 (which may comprise anysuitable third surface mirror reflector, such as a third surfacetransflective mirror reflector or the like). For example, the thirdsurface mirror reflector 820 may be similar to the CAZ reflectordescribed above, may include a layer 820 a of environmentally stablemetallic material, such as chromium or the like, disposed on the frontsurface of the rear substrate (i.e. the third surface of theelectrochromic cell), and a layer or layers 820 b of metal/transparentconductive material/materials over the chromium layer 820 a. The thirdsurface mirror reflector 820 includes a wraparound portion or taboutportion 821 that wraps around and overcoats a perimeter edge 814 c ofthe rear substrate 814 to establish electrical conductivity between thethird surface mirror reflector 820 and a fourth surface electricalcontact 840 a via a fourth surface wraparound portion or coating orlayer 838, such as in a similar manner as discussed above (and which maycomprise an environmentally stable stack of metallic conductive layers,such as a chromium layer 838 a and a ruthenium layer 838 b disposed overchromium layer 838 a). The wraparound portion 821 may extend oversubstantially the entire edge portion 814 c of the rear substrate 814 ormay extend only partially over the edge portion 814 c (such as shown inFIG. 29), with the fourth surface wraparound portion 838 extendingpartially or entirely over the wraparound portion 821 so as to establishelectrical conductivity between the wraparound portions 821 and 838.

An electrochromic medium 816, such as an electrochromic solid polymermatrix (SPM) or other suitable electrochromic medium (such as a liquidor solid electrochromic medium), is disposed between the coated rearsubstrate 814 and a coated front substrate 812 (such as in a 110interpane gap between the substrates and coatings/layers) and sealedwithin the interpane cavity via a perimeter seal 822 (such as an epoxyseal). The third surface mirror reflector 820 is disposed substantiallyover the entire third surface 814 a except at a gap portion or isolatingportion 814 e at a portion of the third surface along and inboard orperimetally inward of the perimeter edge 814 d (or in other words isdisposed over the third surface with the perimeter portion masked duringthe deposition process) so as to define a gap or isolating portion 814 eat the third surface 814 a where the third surface mirror reflector isnot disposed. The gap or isolating portion 814 e may extend along theperimeter edge region about 1 to 2 cm (or thereabouts or more or less)and functions to electrically insulate or isolate the third surfacemirror reflector from the perimeter edge region and overhang region 815of the reflective element at that portion of the edge region. Theperimeter seal 822 is disposed at the gap portion and may overlap anedge portion of the third surface mirror reflector to furtherelectrically insulate or isolate the third surface mirror reflector 820from the perimeter edge region 814 d of rear substrate 814. The thirdsurface mirror reflector 820 may extend over substantially the entirethird surface 814 a except at the gap portion (and thus may extend tothe perimeter edge 714 d at other areas at either side of the gapportion), such that the gap portion may be established by masking arelatively small portion of the third surface during the deposition ofthe third surface mirror reflector materials on the third surface orfront surface of the rear substrate.

The front glass substrate 812 has a transparent electrical conductor 818(such as a coating or layer of ITO or the like) disposed on its rear orsecond surface 812 a. As shown in FIG. 29, a perimeter band 826 (whichmay comprise any suitable material, such as chromium or the like) may bedisposed around the perimeter region of the rear surface of the frontsubstrate 812, with the transparent electrical conductor 818 overlappingthe perimeter band 826. Optionally, however, the transparent electricalconductor may be disposed over the rear surface of the front substrateand the perimeter band may be disposed over the transparent electricalconductor, without affecting the scope of the present invention. Theperimeter band 826 includes a wraparound portion or tabout portion 826 adisposed over a perimeter edge 812 b of front substrate 812 (such asabout a 1 to 2 cm length or portion along the perimeter edge 812 b),while the transparent electrical conductor 818 likewise includes awraparound portion or tabout portion 818 a that is disposed over (orcould be under depending on the particular application) the wraparoundportion or tabout portion 826 a of perimeter band 826 at the perimeteredge 812 b of front substrate 812. The tabout portions 818 a, 826 a areformed along a portion of the perimeter edge 812 b of front substrate812 that corresponds to the location of the gap portion 814 e at thethird surface 814 a of rear substrate 814 when the substrates 812, 814are juxtaposed, such that the third surface reflector 820 is notcoincident with or opposing the tabout portion 818 a, 826 a of thesecond surface transparent conductor of the front substrate.

Thus, the perimeter metallic band 826 may be disposed around the entireperimeter region of the rear surface of the front substrate and thesecond surface transparent conductor 818 may be disposed over the entiresecond surface and over the metallic band. The second surfacetransparent conductor may also be disposed at a wrap around or tab outportion of one edge, such as only about 1 to 2 cm or thereabouts (ormore or less) along one of the edges of the front substrate. The thirdsurface mirror reflector may be disposed over the third surface (thefront surface of the rear substrate) except at a corresponding portionor region of the front surface of the rear substrate that correspondswith or opposes the second surface transparent conductortabout/wraparound portion when the substrates are juxtaposed. The thirdsurface mirror reflector thus may be disposed over the front surface ofthe rear substrate with a mask portion or element only at the portion ofthe front surface that corresponds to and opposes the second surfacetransparent conductor tabout/wraparound portion of the front substrate.

A wraparound element or tabout element or portion 842 is disposed at theperimeter edge 814 d of rear substrate 814 and at the gap portion 814 e(such as about a 1 to 2 cm length or portion along the perimeter edge)of rear substrate 814 (and thus at a location along the perimeter edgethat corresponds to the location of the tabout portion 826 a, 818 a atthe front substrate 812 when the reflective element assembly isassembled together and the front and rear substrates are juxtaposed asshown in FIG. 29). As can be seen in FIG. 29, the tabout portion 842 maybe disposed partially at the rear surface 814 b of the rear substrate814 to establish a fourth surface contact or busbar 840 b, and thetabout portion 842 may be disposed partially at the front or thirdsurface 814 a of the rear substrate and at the region 814 e that isdevoid of the third surface reflector 820. Thus, electrical conductivitymay be established between the fourth surface contact 840 b at thefourth surface 814 b of rear substrate 814 via a conductive element ormaterial 819 (such as a conductive epoxy or the like) established ordisposed at the overhang region 815 of the reflective element 810 (suchas at the perimeter region 814 d of the rear substrate 814 and theperimeter region 812 b of the front substrate 812), and generally at alocation along the perimeter edge region 814 d that corresponds with thegap portion 814 e and that corresponds with the location of the taboutportions 818 a, 826 a at the front substrate when the front and rearsubstrates are juxtapositioned next to one another. In the illustratedembodiment, the electrically conductive tab or wraparound coating orlayer or element 842 is disposed over a portion of the rear surface 814b and perimeter region 814 d and also partially over the perimeter gapregion 814 e of the front or third surface 814 a of the rear substrate814. The wraparound layer or element 842 is electrically isolated orinsulated from the third surface mirror reflector 820 via the gap (orarea at the third surface that is devoid of the third surface reflector820) and the perimeter seal.

Thus, the conductive epoxy 819 disposed at the overhang region 815contacts and establishes electrical conductivity to the second surfaceelectrical conductor 818 via the wraparound portions 826 a, 818 a atperimeter edge 812 b of front substrate 812, and may provide electricalconductivity to the fourth surface contact 840 b via the wraparoundelement or tab or portion 842 at the corresponding location along theperimeter region of the third surface 814 a of rear substrate 814. Thewraparound portion 818 a (comprising ITO or the like) is desirablydisposed between the wraparound chromium portion 826 a and theconductive epoxy 819 so that the conductive epoxy 819 does not directlycontact the chromium perimeter band 826 and wraparound portion 826 a.Optionally, the electrical conductivity between the wraparound portions818 a, 826 a and the fourth surface contact 840 b may be established bydisposing a conductive material, such as conductive epoxy or the like,at the overhang region and further over the perimeter edge region 814 dof the rear surface. Optionally, the electrical conductivity between thewraparound portions 818 a, 826 a and the fourth surface contact or busbar 840 b may be established by disposing a conductive material, such asa conductive epoxy or the like, at the overhang region and providing ametallic clip or element at the corresponding portion of the perimeterregion of the rear substrate. For example, the conductive material orepoxy may be disposed at the overhang region 815 and over the perimeterregion 814 d and a metallic clip may be slid over the perimeter regionwhile the conductive epoxy is wet to establish electrical conductivitybetween the fourth surface portion of the clip and the conductive epoxyat the overhang region. Other means of establishing such electricalconductivity between the fourth surface of the larger rear substrate andthe second surface wraparound portions at the smaller front substratemay be implemented without affecting the scope of the present invention.

As shown in FIGS. 30 and 30A, reflective element assembly 810 may bedisposed at a mirror support or casing or housing or bezel 850 of aninterior rearview mirror assembly 852. The bezel portion 850 may includea thin, substantially non-structural overlap 850 a at the front surfaceof the front substrate 812, while the oversized rear substrate 814 issupported by a supporting portion 850 b of the bezel portion 850, andthus takes substantially all of the load at the bezel portion 850. Suchconstruction substantially reduces the stresses, such as hoop stresses,applied to the seal 822 and reflective element assembly 810 duringassembly and construction of the mirror assembly, because the bezelprimarily contacts the larger dimensioned rear substrate and preferablymakes little or no contact to the smaller dimensioned front substrate.Further, such construction facilitates the use of a reduced reflectiveperimeter band 826, since the perimeter seal 822 is partially hidden orconcealed by the thin overlap portion 850 a of bezel portion 850. Thesize of the reflective band and the visibility or viewability ordiscernibility of the reflective band thus may be reduced. The overlap850 a may extend or overlap the front surface of the front substrateenough so as to at least partially and preferably substantially cover orconceal the perimeter seal 822. The electrical connection to the secondsurface transparent conductor thus may be made via an electricalconnection at the fourth or rear surface of the rear substrate andoutboard of the perimeter seal and thus hidden from view via the bezelportion 850.

As can be seen with reference to FIGS. 30, 30A and 30B, the smallerfront substrate reflective element construction of FIGS. 30 and 30Aallows the bezel to substantially or primarily or entirely engage andsupport the reflective element at the rear substrate, while primarilynot contacting the front substrate. The smaller front substratereflective element construction thus allows for a smaller bezel overlapportion at the front of the reflective element, as compared to an offsetreflective element construction as shown at 870 in FIG. 30B. In themirror construction of FIG. 30B, a larger bezel 872 is used to containthe cell 874 and to cover up or conceal the perimeter seal of the cell.As shown in FIG. 30B, the reflective element may include a backing plateor structural support and the bezel portion may attach to or snap to arear casing portion or cap portion or the like to assemble the mirrorassembly, such as utilizing aspects described in PCT Application No.PCT/US2004/015424, filed May 18, 2004, and published Dec. 2, 2004 as PCTPublication No. WO 2004/103772 A3 (our file DON01 FP-1150 (PCT)), whichis hereby incorporated herein by reference in its entirety.

For example, and as shown in FIG. 30A, the bezel overlap portion 850 amay extend only about 1 mm over the front surface of the reflectiveelement. As shown in FIG. 30A, the bezel 850 may include the overlapportion 850 a that extends about 2 mm (such as about 2.33 mm as shown inFIG. 30A) from the rear substrate contact or support portion 850 b so asto extend over the front surface of the reflective element about 1 mm orthereabouts (i.e., the 2.33 mm overlap portion extends over or acrossthe overhang region 815 of the reflective element (which is illustratedas being about 1.33 mm) and further over the front surface of thereflective element about 1 mm). Although the dimensions described aboveare shown in FIG. 30A as being relative to the lower chin portion of thebezel portion, similar dimensioned bezel portions may be provided at theupper portion of the bezel. A backing plate or attachment plate 854 maybe provided at the rear of the rear substrate 814 and may extend to thebezel portion 850, such as for securing the reflective element to orwithin the mirror assembly and/or for providing user inputs, such asbuttons or switches or the like, or display elements or illuminationsources or the like, at the bezel portion for viewing and/or access by auser or occupant of the vehicle.

The smaller front substrate reflective element construction of thepresent invention thus allows for a smaller or reduced bezel portionaround the perimeter of the front surface of the front substrate, whileproviding substantial support and retention of the reflective element atthe bezel. The electrical conductive connection to the transparentconductor at the rear of the front or first substrate may be made viawraparound elements and/or conductive elements or materials (such asconductive epoxy or the like), such as described above. Thus, thereflective element may be supported at the bezel with a reduced overlapbezel portion around the front perimeter of the reflective element, andwhile providing for electrical connection to the reflective element orcell at the fourth surface of the reflective element or cell. Electricalconnection or conductive continuity may be made to the second surfacetransparent conductor on the smaller front substrate via the wraparoundor tab out portion at the portion of the perimeter edge of the frontsubstrate.

Optionally, and as shown in FIG. 31, an opaque paint or coating or layer860 may be established or disposed at the rear surface 814 b of the rearsubstrate 814 of the reflective element 810. In applications where thereflective element 810 is a transflective reflective element, theelectrical contacts or tabs 841 at the rear of the reflective elementmay be viewable through the reflective element if they are positionedinboard of the perimeter seal and bezel portion. Thus, it is desirableto establish an opaque coating/layer 860, such as via printing orpainting an opaque material or paint or ink or the like, onto the rearor fourth surface to substantially conceal the electrical contact ortab. The opaque coating/layer 860 may be screen printed or laser jetprinted or ink jet printed or transfer printed, such as via boobyprinting or the like, or otherwise established across the fourth surface(or may be an opaque tape applied to the fourth surface) and partiallyover the fourth surface conductor or bus bar 840 a (optionally, theopaque coating/layer 860 may be disposed onto the rear surface of thesubstrate and the fourth surface conductor 840 a may be disposedpartially over the opaque coating/layer). The electrical contact or tab841 thus may be disposed at the fourth surface and partially over theopaque coating 860 and over or to or in conductive continuity with thefourth surface bus bar 840 a, so that the tab 841 can extend into theviewing area for electrical connection without becoming visible throughthe reflective element. Optionally, the opaque layer may comprise aconductive material, whereby the tab may not be necessary.

Optionally, the mirror assembly may include a logo or message oriconistic display that is formed or established in and through (or atleast partially through) the opaque layer. Optionally, the layer may bepartially transmissive (so its mostly opaque (maybe 3-5% T)) at least ata portion of the opaque or substantially opaque layer, and the mirrorreflective element assembly could have an icon behind the layer, such asan opaque icon or the like. Thus, an illumination source may be locatedat the rear of the reflective element and may be activatable orenergizable to backlight the logo or message or icon so it is viewablethrough the reflective element. The backlit logo or message or icon thusmay be readily viewable or discernible by a person viewing the mirrorreflective element.

For the third surface metallic reflectors, second surface metallicreflectors, second surface metallic reflective bands, second surfaceindicia reflective bands/indicia and/or fourth surface wrap-aroundmetallic conductor layers (such as are described herein and/or disclosedin U.S. patent application Ser. No. 11/226,628, filed Sep. 14, 2005;Ser. No. 11/021,065, filed Dec. 23, 2004, now U.S. Pat. No. 7,255,451;and/or Ser. No. 11/334,139, filed Jan. 18, 2006, now U.S. Pat. No.7,400,435; and/or U.S. provisional applications Ser. No. 60/644,903,filed Jan. 19, 2005; Ser. No. 60/667,049, filed Mar. 31, 2005; and/orSer. No. 60/692,113, filed Jun. 20, 2005, which are hereby incorporatedherein by reference in their entireties), thin film coatings formedpreferably by sputtering of nickel-alloys or iron-alloys can be used.

For example, Inconel (a nickel-based superalloy such as Inconel alloy600 which is 72 percent nickel, 16 percent chromium, and 8 percent iron)can be used. Other forms of Inconel can be used, depending on theproperty required for a particular mirror construction/coating. Forexample, Inconel alloy 750, which has a small percentage of titanium andaluminum added for hardenability, can be used. Another example of asuitable material is Inconel 625, which contains molybdenum andcolumbium.

Another suitable nickel-alloy choice is HASTELLOY, which is a registeredtrademark name of Haynes International, Inc. The predominant alloyingingredient is typically nickel. Other alloying metals may be added tothe nickel, including varying percentages of the elements molybdenum,chromium, cobalt, iron, copper, manganese, titanium, zirconium,aluminum, carbon, and tungsten. For example, for the third surfacemetallic reflectors, second surface metallic reflective bands and/orfourth surface wrap-around metallic conductor layers of theelectrochromic mirrors described herein, thin film coatings may bedeposited on the substrates involved by sputtering in a vacuum chamberfrom a Hastelloy C 276 or a Hastelloy X alloy planar magnetron or rotarymagnetron sputtering target.

Another suitable choice is Nichrome, which is an alloy of nickel andchromium. Typically, the alloy is 80 percent nickel and 20 percentchromium. Nichrome, when sputter deposited as a conductive, metallic,reflective thin film of at least about 300 angstroms thickness has aspecular reflectivity greater than about 60 percent reflectivity; anddepending on the vacuum deposition conditions greater than about 65percent reflectivity (as measured using SAE J964a). For example, goodresults can be achieved using a thin film of Nichrome [typically about400-600 angstroms thick sputter-deposited onto the inward-facing surface(third surface) of the rear substrate in a laminate-type electrochromicmirror cell construction], and then overcoating this thin layer ofNichrome with a thinner layer (typically about 100-200 angstroms thickor thereabouts) of Rhodium to form a Nichrome/Rhodium third surfacereflector. If Nichrome is also used as a wrap-around fourth surfaceconductor [or for the perimetal reflector band around the edge perimeterof the inward-facing surface (second surface) of the front substrate ofthe EC cell construction], contact resistance challenges sometimesexperienced when a chromium thin film conductor layer is contacted to bysome silver-loaded conductive epoxies are reduced/mitigated.

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayers is a coating of Nickel Silver, which is an alloy of copper withnickel and often, but not always, zinc. Nickel-silver alloys arecommonly named by listing their percentages of copper and nickel, thus“Nickel Silver 55:18” would contain 55 percent copper, 18 percentnickel, and 27 percent other elements, most probably entirely zinc. Forexample, a NS-12 Nickel-silver alloy, which is 88 percent copper and 12percent nickel, may be used.

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayers is a coating of Cupronickel which is an alloy of copper, nickeland strengthening impurities. A typical mix is 75 percent copper, 25percent nickel, and a trace amount of manganese. A 55 percent copper/45percent nickel alloy may also be used.

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayers is a coating of Monel metal, which is a copper-nickel alloy.Monel is a metal alloy, primarily composed of nickel and copper, withsome iron and other trace elements. Also, bronze (copper alloyed withtin), brass (copper alloyed with zinc), and nickel silver (another groupof copper-nickel alloys) may be used.

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayers is a coating of stainless steel which is a ferrous alloy with aminimum of 10.5 percent chromium, preferably with additions of more than12 percent (by weight) chromium. For example, a thin film coatingsputtered off a AL-6XN alloy target, which is a superausteniticstainless steel which was developed by Allegheny Ludlum Corporation(www.alleghenyludlum.com), can be used. It exhibits far greaterresistance to chloride pitting, crevice corrosion and stress-corrosioncracking than exhibited by the standard 300 series stainless steels, andis less costly than traditional nickel-base corrosion resistant alloys.The UNS Designation of the AL-6XN® alloy is N08367.

The high nickel (24 percent) and molybdenum (6.3 percent) contents ofthe AL-6XN® alloy give it good resistance to chloride stress-corrosioncracking. The molybdenum confers resistance to chloride pitting. Thenitrogen content of AL-6XN® alloy serves to further increase pittingresistance and also gives it higher strength than typical 300 seriesaustenitic stainless steels, and thereby often allows it to be used inthinner sections. The high levels of chromium, molybdenum and nitrogenin AL-6XN® alloy all serve to produce exceptional corrosion resistancefor this formable and weldable stainless steel.

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayers is a coating of Chinese silver, which is an alloy made of silver,nickel and bronze, such as used for jewelry or a coating of a Ferroalloythat constitutes various alloys of less than 50 percent iron and one ormore other element, manganese or silicon for example. The mainFerroalloys are: ferromanganese, ferrochromium, ferromolybdenum,ferrotitanium, ferrovanadium, ferrosilicon, ferroboron, andferrophosphorus.

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayer is a coating of German silver that is an alloy of 45-70 percentcopper, 5-30 percent nickel, and 8-45 percent zinc—sometimes smallamounts of tin or lead are added. It has a color resembling silver.Other names are Nickel silver, Pakfong (also Paktong) and Alpacca(originally a trademark of Berndorf AG).

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayer is a coating of a titanium alloy such as a Grade F-5 titaniumalloy (6 percent aluminum, 4 percent vanadium); Grade F-6 titanium alloy(5 percent aluminum, 2.5 percent tin); a titanium/palladium alloy; GradeF-12 titanium alloy (0.3 percent molybdenum, 0.8 percent nickel).

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayer is a coating of a manganese alloy, such as a manganese-copper or amanganese-iron or a manganese-gold alloy. Another alloy choice for thesemetal reflector and/or conductor layers is a coating of a molybdenumalloy, such as a 52 percent molybdenum/48 percent rhenium alloy or a 99percent Mo, 0.5 percent Ti and 0.08 percent Zr alloy (commonly known asa TZM alloy).

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayer is Sterling silver, which is an alloy of silver containing least92.5 percent pure silver and 7.5 percent other metals, usually copper.In Sterling silver, the silver is usually alloyed with copper to givestrength. Other metals can replace the copper. For example, a thin filmcoating formed by sputter deposition from a Silver/Germanium alloytarget can be used.

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayer is an aluminum alloy, such as Duralumin which is an alloy ofaluminum (about 95 percent), copper (about 4 percent), and small amountsof magnesium (0.5 percent to 1 percent) and manganese (less than 1percent). When sputter deposited to form a thin film metallic conductorreflector/electrode layer, such aluminum alloy thin films may optionallybe overcoated with a thin film of a transparent conductor (such as ofindium tin oxide) that is thus disposed between the aluminum-basedreflector layer and the electrochromic medium in the electrochromic cellconstruction (and thus protecting the aluminum-based reflector layerfrom direct contact with the electrochromic medium).

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayer is Stellite, which is a range of cobalt-chromium alloys designedfor wear resistance. It may also contain tungsten and a small butimportant amount of carbon.

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayer is Billon, which is an alloy of silver (sometimes gold) with ahigh base metal content (such as copper) or a silver alloy such as asilver-palladium alloy.

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayer are copper-zinc-aluminium alloys or nickel-titanium (NiTi) alloys,such as the nickel-titanium alloy available under the trade name Nitinol(an acronym for Nickel Titanium Naval Ordnance Laboratories).

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayer are tungsten alloys with tungsten content ranging from 40 to 97percent featuring varying degrees of physical and mechanical properties;examples include W—Fe, W—Cu and W—Co alloys.

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective hands/indicia and/or fourth surface conductorlayer are palladium alloys, such as palladium-rhodium alloys.

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayer are indium alloys, such as indium-bismuth-tin alloys orlead-indium alloys or tin-indium alloys.

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayer are zinc alloys, such as with copper or magnesium or nickel.

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayer is Brass, which is an alloy of copper and zinc. Some types ofbrass are called bronzes, despite their high zinc content. Alpha brasses(with less than 40 percent zinc) or Beta brasses, with a higher zinccontent, can be used, depending on the circumstance involved. Whitebrass, with more than 45 percent zinc, can also be used when it deliversthe desired property.

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayer is a rhenium alloy, such as a molybdenum-rhenium or atungsten-rhenium alloy.

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayer is a gold alloy such as an ELKONIUM® 76 gold-copper alloy or anELKONIUM® 70 gold-silver-nickel alloy or a gold-palladium-nickel alloyor a gold-copper alloy or a gold-copper-nickel alloy or a gold-indiumalloy or gold-nickel alloy or a gold-tin alloy.

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayer is a platinum alloy, such as with cobalt, or with copper or withiridium (for example, Pt70/Ir30) or with palladium or with rhodium orwith gallium or with ruthenium or with tungsten or with indium.

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayer is a rhodium alloy, such as with iron or platinum (for example,Pt90/Rh10 or Pt87/Rh13).

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayer is a cobalt alloy, such as with iron or nickel.

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayer is a copper alloy, such as with tin or nickel or lead. Examplesinclude Phosphor Bronze, Gun Metal, Tin Bronze, Leaded Bronze and NickelBronze.

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayer are superalloys, such as PM200 available from Plansee AG ofReutte, Austria, and having a composition in weight percentage: 20 Cr,5.5 Al, 0.5 Ti, 0.3 Al, 0:5 Y₂O₃, remainder Fe. The Plansee PM 2000 is ahighly oxidation resistant and extremely creep resistant ferriticiron-chromium based alloy, due to its high content of aluminum andchromium.

Another alloy choice for these third surface metal reflector layers,second surface indicia reflective bands/indicia layers and/or fourthsurface conductor layers are tantalum alloys, such as tantalum-tungstenalloys and tantalum-niobium alloys. Another alloy choice for these metalreflector and/or conductor layers are niobium alloys or zirconium oriridium alloys or osmium alloys or ruthenium alloys or lead alloys orberyllium alloys or tin alloys.

Alloys formed of tin and lead with other metal elements and non-metalelements (such as phosphorous or silicon or carbon) may be used wherethe coating properties suit the particular electrochromic cellstructure/performance desired.

Another alloy choice for these third surface metal reflector, secondsurface indicia reflective bands/indicia and/or fourth surface conductorlayer is a magnesium alloy, such as Magnesium-manganese;Magnesium-aluminum-manganese; Magnesium-aluminum-zinc-manganese;Magnesium-zirconium; Magnesium-Zinc-zirconium; Magnesium-rare earthmetal-zirconium; Magnesium-silver-rare earth metal-zirconium; and/orMagnesium-yttrium-rare earth metal-zirconium.

Metal reflector layers and/or indicia layers and/or conductor layers mayalso be sputter (or otherwise) deposited from metal targets such as froma chromium metal target, or from a nickel metal target or from atungsten metal target or from a ruthenium metal target or from atitanium metal target or from a molybdenum metal target or from a cobaltmetal target or from a manganese metal target or from a silver metaltarget or from an aluminum metal target or from a platinum metal targetor from a palladium metal target or from a gold metal target or from arhenium metal target or from a rhodium metal target or from a tantalummetal target or from a niobium target or from a zirconium target or froman iridium target or from an osmium target or from a lead target or froma beryllium target or from a zinc target or from a tin target or from anindium target or from a target that is a mixture of one or more of thesemetals (optionally with other metallic and/or non-metallic elementsincluded). In general, improved results in terms of making contactthereto, such as via a conductive epoxy (such as lower, stabler contactresistances), are obtained for metal reflector and/or conductor layersby using metals or alloys that have a low Gibbs Energy of formation ofmetal oxides as the sputter target (or evaporation material) for vacuumdeposition of thin metallic layers. For example, deposited thin films ofpalladium or nickel or tungsten or molybdenum or rhodium have a lowGibbs Energy of formation of metal oxides compared to, for example, thinfilms of aluminum or chromium.

The choice of alloy or metal reflector and/or conductor layer to use isdependent on the reflectivity level and spectral content desired (forexample, whether a silvery reflectivity is desired or whether a morecopper-toned reflectivity is desired) and by the electrical properties(such as specific conductivity of the deposited thin film) and/oroptical properties (such as the optical constants such as refractiveindex and k-value) desired for the deposited thin metallic film and/orby the sputtering rate/evaporation rate desired in the productionprocess and/or by the cost bearable by the construction involved.

Also, when sputtering or otherwise vacuum depositing the metal reflectorand/or conductor layers of the present invention from an alloy ormixed-metal target or source, the elemental composition/structure of thetarget/source is preferably substantially replicated in the depositedmetallic thin film coating or layer but need not be exactly replicated.

Also, and as described previously above and optionally, the thirdsurface metal reflector on the third surface of the rear substrate ofthe cell, the perimeter reflective border band around the edge border ofthe second surface of the front substrate and any indicia on the secondsurface but inward of the border band (if present) may be substantiallythe same material so that all three have substantially the same opticalproperties such as reflectivity level and refractive index /k-value. Byso choosing, the optical contrast between the third surface reflectorcoating and the second surface perimeter border is substantially reducedand essentially eliminated such that the viewer barely sees or noticesthe presence of the second surface border band when the electrochromiccell is not powered (i.e. is undimmed and is in its bleached state). Forexample, the third surface reflector coating and the second surfaceperimetal border reflector band may both comprise chromium thin films orboth may comprise ruthenium thin films or both may comprise rhodium thinfilms or both may comprise Hastelloy C-276 thin films or both maycomprise molybdenum thin films or both may comprise aluminum (oraluminum alloy) thin films or both may comprise aluminum/palladium alloythin films or both may comprise silver (or silver alloy) thin films orboth may comprise an ITO/thick Ag (preferably greater than about 200angstroms physical thickness; more preferably greater than about 250angstroms thickness and most preferably greater than about 300 angstromthickness)/ITO stack or a ZnAlO/thick Al/ZnAlO stack or a ZnAlO/thickAg/ZnAlO stack or an SnO2/Ag/SnO2 stack or the like.

Optionally, it may be desirable to select a bezel for a mirror assemblythat has a material or color or appearance or construction orreflectance character that matches or accentuates or complements thereflective surface of the interior mirror (or exterior mirror)reflector, and particularly for an interior EC mirror element that usesa reflecting perimeter border band or coating (such as disclosed in U.S.patent application Ser. No. 11/021,065, filed Dec. 23, 2004, now U.S.Pat. No. 7,255,451; Ser. No. 10/528,269, filed Mar. 17, 2005, now U.S.Pat. No. 7,274,501; Ser. No. 10/533,762, filed May 4, 2005, now U.S.Pat. No. 7,184,190; Ser. No. 11/226,628, filed Sep. 14, 2005 (AttorneyDocket DON01 P-1236); and/or Ser. No. 11/021,065, filed Dec. 23, 2004,now U.S. Pat. No. 7,255,451, which are hereby incorporated herein byreference in their entireties) in a flush or frameless EC minor cellconstruction. The bezel of the mirror casing and the perimeter metalband around the perimeter of the reflective element are preferablyselected so as to mutually pick up on or complement each other so as toenhance the appearance and utility of the mirror assembly. The mirrorassembly thus may include the use of a metal (or metal-like ormetal-coated) bezel that can pick up on or complement the framelesscharacter of the mirror element, and give the minor assembly ametal-look functionality. For example, and as shown in FIG. 32, a mirrorassembly 910 includes a mirror reflective element 912 having a perimetermetallic band 914 (with a metallic or silvery appearance or color). Themirror assembly 910 includes a bezel portion 916 that is selected tosubstantially match or contrast the color or appearance or reflectanceof the perimeter metallic band 914. In the illustrated embodiment, theperimeter band has a silvery appearance or color, and the bezel portion916 is selected to have a silver or chrome appearance or color orreflectance. Thus, for reflective elements with metallic perimeter bands(or other mirror reflector types), the bezel portion may comprise ametallic material (such as a silvery or brass-like metal stamping orforming or a chromed or metal-coated plastic molding) so as to have ametallic or metal-like appearance. The bezel portion thus picks up orcomplements the perimeter band of the minor reflective element (or themirror reflector itself) so as to provide an aesthetically pleasingmirror assembly. Although shown in FIG. 32 as an interior rearviewmirror assembly, the mirror assembly may comprise an exterior rearviewmirror assembly utilizing similar principles. Thus, a retro-look orhigh-tech look can be imparted to the mirror assembly and the look tothe driver or occupants of the vehicle of the bezel can blend in withthe look of the mirror reflective element itself.

Optionally, the mirror assembly may include one or more displays, suchas for the accessories or circuitry described herein. The display ordisplays may be similar to those described above, or may be of the typesdescribed in U.S. Pat. Nos. 5,530,240 and/or 6,329,925, which are herebyincorporated herein by reference in their entireties, or may bedisplay-on-demand or transflective type displays or other displays, suchas the types disclosed in U.S. Pat. Nos. 6,690,268; 5,668,663 and/or5,724,187, and/or in U.S. patent application Ser. No. 10/054,633, filedJan. 22, 2002, now U.S. Pat. No. 7,195,381; Ser. No. 11/021,065, filedDec. 23, 2004, now U.S. Pat. No. 7,255,451; Ser. No. 10/528,269, filedMar. 17, 2005, now U.S. Pat. No. 7,274,501; Ser. No. 10/533,762, filedMay 4, 2005, now U.S. Pat. No. 7,184,190; Ser. No. 10/538,724, filedJun. 13, 2005 (Attorney Docket DON01 P-1123); Ser. No. 11/226,628, filedSep. 14, 2005 (Attorney Docket DON01 P-1236); Ser. No. 10/993,302, filedNov. 19, 2004, now U.S. Pat. No. 7,338,177; and/or Ser. No. 11/284,543,filed Nov. 22, 2005, now U.S. Pat. No. 7,370,983, and/or PCT ApplicationNo. PCT/US03/29776, filed Sep. 9, 2003 by Donnelly Corp. et al. forMIRROR REFLECTIVE ELEMENT ASSEMBLY; and/or PCT Application No.PCT/US03/35381, filed Nov. 5, 2003 by Donnelly Corp. et al. forELECTRO-OPTIC REFLECTIVE ELEMENT ASSEMBLY; and/or U.S. provisionalapplications Ser. No. 60/630,061, filed Nov. 22, 2004; Ser. No.60/667,048, filed Mar. 31, 2005; Ser. No. 60/629,926, filed Nov. 22,2004; Ser. No. 60/531,838, filed Dec. 23, 2003; Ser. No. 60/553,842,filed Mar. 17, 2004; Ser. No. 60/563,342, filed Apr. 19, 2004; Ser. No.60/681,250, filed May 16, 2005; Ser. No. 60/690,400, filed Jun. 14,2005; Ser. No. 60/695,149, filed Jun. 29, 2005; Ser. No. 60/717,093,filed Sep. 14, 2005; Ser. No. 60/730,334, filed Oct. 26, 2005; Ser. No.60/732,245, filed Nov. 1, 2005; and/or Ser. No. 60/759,992, filed Jan.18, 2006, and/or PCT Application No. PCT/US03/40611, filed Dec. 19, 2003by Donnelly Corp. et al. for ACCESSORY SYSTEM FOR VEHICLE, which are allhereby incorporated herein by reference in their entireties, or mayinclude or incorporate video displays or the like, such as the typesdescribed in PCT Application No. PCT/US03/40611, filed Dec. 19, 2003 byDonnelly Corp. et al. for ACCESSORY SYSTEM FOR VEHICLE, U.S. patentapplication Ser. No. 10/538,724, filed Jun. 13, 2005 (Attorney DocketDON01 P-1123); and/or Ser. No. 11/284,543, filed Nov. 22, 2005, now U.S.Pat. No. 7,370,983, and/or U.S. provisional applications Ser. No.60/630,061, filed Nov. 22, 2004; and Ser. No. 60/667,048, filed Mar. 31,2005, which are hereby incorporated herein by reference in theirentireties.

Optionally, the mirror assembly and/or reflective element assembly (suchas a transflective electro-optic or non-electro-optic mirror reflectiveelement) may include or may be associated with a rearwardly facing videodisplay screen, such as a video display screen positioned at and behindthe fourth surface of the reflective element and operable to emit lightthrough the reflective element so as to be viewable to a driver of thevehicle when actuated. Typically, the intensity of the display ismaximized during daytime operation (such as bright ambient lightconditions) to reduce or limit washout of the display. However, atnight, the intensity may be reduced, such as via photo-sensor control orby applying a reduced voltage when vehicle logic adapts an instrumentpanel dimmed illumination state. Accordingly, visibility of the displayat night (i.e., during low or reduced ambient light conditions) isreadily accomplished for such displays as the intensity of the displayemission can be readily reduced by applying a reduced voltage comparedto that applied when the display intensity is maximized during daytimedriving. However, when an electro-optic (such as electrochromic)reflective element is dimmed or darkened at night in response to adetected glaring headlight condition, it may be desirable to re-brightenthe intensity of the display (such as a navigation display or the like)to compensate for the reduced transmission through the electro-opticmedium and thus enhance visibility and discernibility of the displaythrough the darkened or dimmed reflective element, such as by utilizingaspects of the system described in U.S. Pat. Nos. 5,285,060 and5,416,313, which are hereby incorporated herein by reference in theirentireties. Also, when the electro-optic medium is dimmed, such dimmingmay introduce a spectral characteristic or tint at the display and/ormay impact the color rendition and/or color balance of a displayed colorvideo image. Thus, and as described below, it may be desirable to avoidactuation and hence darkening/dimming of the electro-optic medium localto and in front of where the video display is disposed behind thereflective element.

For backup applications, such as a display that displays a rearward viewat the rear of the vehicle, such as in conjunction with reverse aid orbackup systems, such as a display that emits a video image of therearward scene in response to a rearward facing video camera, theelectro-optic mirror element may function in association with a reverseinhibit function (where the dimming of the electro-optic reflectiveelement is inhibited when the reverse gear of the vehicle is engaged,such as described in U.S. Pat. Nos. 6,992,573; 6,590,193; 6,547,404;6,305,807; 6,089,721; and 5,812,321, which are hereby incorporatedherein by reference in their entireties), whereby the mirror reflectiveelement is forced to and maintained in its day state when the vehicle isshifted into its reverse gear. In such backup or rear vision systemapplications, it may be desirable to locally dim the electro-opticmedium in front of where the display is located behind the reflectiveelement. Alternatively, and in particular applications, preferably, anelectro-optically dimmed or darkened frame may be electro-opticallycreated adjacent to and around where the video display is disposed(behind the reflective element) so as to frame the display for enhanceviewability and discernibility of the display at and behind thereflective element. For example, and with reference to FIG. 33, areflective element assembly 920 may be segmented into a primaryreflective element viewing area or region D and a video display viewingarea or region B, with the video display viewing area B at leastpartially surrounded or framed by a framing area or portion or region A.

Optionally, a lower frame portion or area or region C may be providedalong the lower portion of the video display viewing area B, with a pairof leg portions of the video display viewing area B extending to theperimeter of the reflective element 920 at opposite sides of lower frameportion C and between lower frame portion C and frame portion A. Thesize or length of frame portion or region C may be selected depending onthe desired or appropriate size or width of the legs of display area B,since the legs provide the conductive path to display area B and theelectric flow to display area B may be reduced as the legs are made morenarrow. Optionally, the reflective element may have a perimeter borderband (such as described above), and the lower frame portion may not bereadily viewable at the lower perimeter band, such that the reflectiveelement may not include such a lower frame portion.

The different portions or areas or regions A, B, C, D are defined bydemarcation lines or deletion lines through at least one or some of theconductive coating or coatings of the reflective element 920 so as toelectrically isolate one region from another and so as to enableelectrical powering, and hence local actuation and dimming, of theelectro-optic medium at each particular segment or region separate fromthe others. The demarcation lines are formed to electrically isolate theadjacent regions, while being sufficiently thin so as to be largelyunnoticeable to the viewer of the mirror element. Preferably, thedeletion lines are formed through the transparent conductive layer (suchas ITO or the like) disposed on the second surface or rear surface ofthe front substrate of an electro-optic reflective element, such as bylaser ablating or deleting thin lines along the second surface to definethe desired viewing portions. Optionally, the deletion lines may beformed in and through the third surface reflector coatings or layers,but such deletion lines in the third surface reflector may be morereadily visible or discernible than deletion lines formed through thesecond surface transparent conductive coating or layer.

Thus, during normal dimming or anti-glare operation of the reflectiveelement 920, all of the regions A, B, C, D are powered to dim theviewable area of the reflective element. Optionally, the reflectiveelement may be selectively dimmed, such as by dimming or darkeningregions A and C (such as by powering contacts or electrodes at E andgrounding or shorting contacts or electrodes at F) so as to provide adarkened frame around the video display and display area B. Suchselective dimming may occur in response to the vehicle being shiftedinto its reverse gear. Such a frame enhances the viewability of thedisplay by drawing the driver's eyes to the display area B when theframe is dimmed and the other viewing regions are not. Optionally,either the main or principle viewing/reflecting area D or the displayarea B may be dimmed while the other is un-dimmed or unpowered, in orderto provide the desired reflectivity and viewability of the reflectiveelement and display, depending on the particular application and desiredappearance and function of the reflective element assembly.

In this manner, the presence and viewability of a video image displayedon such a video display/screen disposed behind a transflectiveelectrochromic mirror element may be enhanced even during usage by dayunder higher ambient lighting (sunny) conditions where display wash-outcan be a problem. The localized darkening of the EC medium local to andat least partially framing (preferably, substantially or wholly framing)the portion of the EC mirror element where the video screen is disposedduring daylight operation as described above helps draw the driver'sattention and focus to the potentially faint/washed-out video image(such as a reversing back-up scene) and helps the driver distinguishthis from the much brighter reflected image from the mirror reflector atother than where the video display is disposed.

This discrimination can be further augmented by increasing the intensityof display backlighting and or provision of additional lighting at butjust beyond the border peripheral edges of the display element so that aring or at least a partial frame of intense light can be seen by thedriver that at least partially frames where the video screen is located(and so draws his/her attention and eye-focus to that location). Such anintense-light created frame or the like can be also used with aconventional fixed reflectance transflective mirror element (such as atransflective day/night prismatic mirror element)/video display asdescribed above [with or without demarcation lines being ablated, suchas by laser ablation, into the minor reflector's coating(s)]. Such aring or frame of intense light may be created, for example, by disposingbehind the minor element a number of intense light sources (such as LEDsor diode lasers or cold cathode tubes) that at least partiallycircumscribe the video display element at the rear of the mirrorreflector, but that are located close to but just outside the displayelement itself so that the light emitted by such, for example, LEDs doesnot pass through (and so be attenuated by) the display element itself,(typically, an LCD video display element). For example, a linear row ofa plurality of LEDs, such as 3-6 LEDs or more, can be positioned along(but just outside) the top edge, along the bottom edge, along the rightedge and/or along the left edge, so as to frame the location of thevideo display via emitting intense light through the transflectivereflector of such a DOD transflective electrochromic ornon-electrochromic (conventional) through-the-reflector video mirror.

Optionally, the likes of light pipes/light conduits and lightdistributors/diffusers (such as are common in the art) can be used inconjunction with an LED or a couple of LEDs or a plurality of LEDs increating such a frame of intense light that at least partially framesthe video display image so that its visibility and viewability to thedriver is enhanced during daylight operation and so that the driver canbetter discern and focus on the video image being displayed, even underwash-out conditions. Optionally, the likes of photosensors can be usedto adjust the intensity of such framing light sources (that preferablyare LEDs but that alternatively can be a cold-cathode tubular lightsource, such as light sources of the types described in U.S. provisionalapplications Ser. No. 60/732,245, filed Nov. 1, 2005; and Ser. No.60/759,992, filed Jan. 18, 2006, which are hereby incorporated herein byreference in their entireties, or can be any other suitable intenselight source, such as a diode laser light source or a high-intensityincandescent light source) in accordance with prevailing ambient lightconditions (and so that at night, intensity is reduced but by day,intensity is increased in accordance with an increase in ambientlighting detected). Note that it may be preferable to use a red or anyother selected spectral intensity/color for the ring or frame of intenselight created around the video image so that the demarcation createsboth spectral demarcation and light intensity demarcation relative tothe light intensity and spectral character of the video image itself.

Typically, it is desirable to substantially render unnoticeable orcamouflage the presence of the video display (such as a liquid crystaldisplay (LCD) video display or the like) that is disposed behind atransflective mirror element, such as a transflective mirror elementthat is at least about 10 percent transmissive of light therethrough andpreferably about 20 percent transmissive. It is known to use a dark orblack tape (or other suitable darkening or opacifying materials orlayers, such as dark paint or ink or the like) to black out or opacifythe areas where the display is not present, so that the presence of thedisplay is not readily discernible to a person viewing the reflectiveelement. However, this may lead to the joint lines between the tape andthe display being visible or discernible, and even with such opacifyingmeans, the outline of the display or display area may be noticeable tothe driver, particularly during high ambient lighting conditions, suchas during daytime driving conditions.

Optionally, a video display framing element or pocket may be provided asfollows that is surprisingly effective in rendering the presence behinda transflective mirror element (and an interior prismatic transflectivemirror element in particular) of the un-illuminated video screennon-noticeable. A piece of metal shim stock, such as stainless steel(such as a sheet or shim of stainless steel having a thickness of about0.01 inches to about 0.02 inches or thereabouts) or the like, may belaser cut to match the shape of the prism or reflective element. Theshim stock stainless steel substrate may have a window formed or lasercut therefrom that matches or substantially matches the size and shapeof the active area of the display screen. Desirably, the color,reflectance and gloss of the shim stock substrate is selected tosubstantially match the OFF condition of the video display screen. Thevideo display screen may be located at and behind the window of the shimstock substrate, and may be secured or adhered or glued or fastened inplace at the window. The display element and shim stock substrateassembly may be located at or attached to the reflective element andbehind the display on demand (DOD) reflective element.

The presence and location of the video display is thus substantiallycamouflaged or hidden or non-discernible so that it may be difficult toidentify or discern the location of the video display when viewing thereflective element. The display assembly (including the shim stock plateor substrate and display element attached thereto) may be attached oradhered to the rear of the reflective element, such as to the rear of abacking plate of the reflective element or to the rear surface of aprismatic reflective element substrate or prism. Optionally, the displayassembly may be attached or adhered to the rear surface of a prismaticreflective element substrate, such as an aluminum and silicon layeredtransflective prism, such as a prismatic substrate or element utilizingaspects of the mirrors described in U.S. Pat. Nos. 6,286,965; 6,196,688;5,535,056; 5,751,489; and 6,065,840, and/or in U.S. patent applicationSer. No. 10/993,302, filed Nov. 19, 2004, now U.S. Pat. No. 7,338,177,which are all hereby incorporated herein by reference in theirentireties.

Optionally, a non-electro-optic transflective or display-on-demand (DOD)mirror element, such as a transflective prismatic mirror element, may beformed using a transflective DOD coating or coating stack on its secondsurface. Preferably, the coating or coating stack may comprise a coatingcomprising silicon or doped-silicon, such as silicon-aluminum mirrorstack (with high silicon content) deposited onto the substrate surface.Such a silicon or doped-silicon coating may provide about 70 percent ormore reflectivity of light incident thereon, while providing at leastabout 10 percent or more transmission of light therethrough, typicallyat least 20 percent or more transmission. The reflectivity from such asilicon-based coating may provide a silvery appearance and may provideenhanced durability to the substrate surface. Such a silicon-basedmirror stack may be suitable for a transflective display on demand (DOD)prismatic substrate, such as for an interior or exterior rearview mirrorassembly. Such a transflective silicon-based minor element is suitablefor use with a video display located behind the mirror so as to displayvideo images at the mirror element for viewing by the driver of thevehicle. Alternately, similar silicon-based transflective mirrorelements can be formed for exterior or outside minor elements, such asflat, convex or aspheric elements (optionally, with the transflectivelayers on the front or first surface or on the rear or second surfaces,such as is known in the exterior minor arts).

Optionally, a mirror reflective element may comprise a transflectivedisplay-on-demand (DOD) reflective element having suitable transflectivecoatings or layers on the third surface or fourth surface of anelectro-optic reflective element, or on the first surface or secondsurface of a single substrate conventional fixed reflectance reflectiveelement. Desirably, a mirror substrate may have a silicon ordoped-silicon coating or other suitable coating on its transflectivesurface. For example, mirror reflective elements for use in automobilesmay utilize, in forming their substrates, transflective reflector-coatedglass sheets having silicon-based transflective coatings or othersuitable material, such as transflective reflector-coated glass sheetsof the type that is commercially available from Pilkington of Toledo,Ohio and marketed under the trade name Mirropane T.M.™ TransparentMirror Glass. Such silicon-based transflective coated glass sheets mayhave a reflectivity of at least about 70 percent of light incidentthereon and a transmissivity, even in grey, of at least about 11percent, and if clear glass, its transmissivity may be higher, such asup to about 20 percent or more. To manufacture an interior minorprismatic element from such commercially available transflectivereflector-coated glass sheets or substrates or panels, large, thick(such as about 6 mm to 6.6 mm thick or thereabouts) silicon-basedtransflective mirror glass sheets (preferably with the transflectivereflector coating(s) coated onto non-tinted, highly light transmittingclear glass) may be purchased from Pilkington or another manufacturer.The transflective reflector-coated glass sheets may then be cut tointerior mirror sized shapes or dimensions, which in turn may be groundto a prism wedge and edge finished to form the desired silicon-basedtransflective interior prismatic minor elements suitable for use ininterior automotive rearview minor assemblies as a flip ormanually-operated day/night mirror, as is known in the art. Such aprocess benefits from advantages such as its superior durability andchemical inertness of the silicon-based reflector during the prismmanufacturing operations(s). Optionally however, a transparent tape, orcoating may be disposed over the reflector of the transflectivereflector-coated glass as a protectorant prior to and during the prismfabrication process. Note that the silicon-based transflective mirrorreflector coating is on the second surface opposite to the groundprism's slanted front surface of the mirror shape.

For a transflective interior mirror element behind which a video screenwill be disposed as part of a display-through-the-mirror element videomirror/reversing camera system or the like, a clear, light transmittinglayer or film may be used to environmentally and/or physically protector encapsulate the mirror reflector coating or coatings at the secondsurface of the prismatic glass element. Suitable materials to useinclude encapsulants and conformal coatings commonly used in theelectronics industry, and such as are available for CDs and DVDs, suchas SK3200 and similar materials from Sony Chemicals or Shinetsu moisturecure silicone or Dymax 3095 or Loctite 3493 or Emerson & Cuming UV 7993.Such coatings can be applied by screen printing, dipping, spraying,roller coating, pad printing, ink jet printing and the like, and may becured chemically or by heating or by UV exposure or the like. It isdesirable to avoid any voids or bubbles or inclusions in the appliedoptically clear coating/film and that the applied coating/film be clearand highly light transmitting and be uniform in thickness. Optionally, aflexible sheet of plasticized PVB or of silicone or similar opticallyclear and transparent flexible film sheet may be laid over the secondsurface coating, and then vacuum-assisted/heating means (such as aredescribed in U.S. provisional applications Ser. No. 60/732,245, filedNov. 1, 2005; and Ser. No. 60/759,992, filed Jan. 18, 2006, which arehereby incorporated herein by reference in their entireties) can be usedto conform and attach to the coated second surface of the prism shapeand so encapsulate/protect.

Even for the likes of a silicon-based second surface reflector, butparticularly if a more environmentally fragile transflective reflector,such as of ITO/Ag/ITO, is used, it is desirable and preferred to protectwell the exposed edges at the border edges around second surface of theprism part or substrate. In this regard, it is desirable either to maskclose to the edges so that the reflector coating is not formed right outto the very edge and so that any encapsulant or conformal coating orsheet or means used can extend out to the very edge and/or to ensurethat any encapsulant or conformal coating or sheet or means usedactually wraps around the cut edge to form a wrap-aroundencapsulant/protectorant that mitigates or prevents edge corrosion.

If a metal oxide/metal/metal oxide transflective stack, such asITO/Ag/ITO (ISI), is used as the mirror transflector, clear opticalconformal coatings, such as acrylics or silicones or epoxies (that maybe chemically cured or thermally cured or UV cured or microwave cured)or the like, can beneficially have the effect of flattening any spectralcharacter of the thin film stack by acting as a massive layer (thephysical thickness of the conformal coating or similar polymericencapsulating layer may be many microns in thickness whereas the thinfilm ISI coatings are only several nanometers in thickness). Forexample, and for a typical ISI transflective mirror reflector coatedonto the second surface of a cut glass prism shape, photopic reflectionrose by about 6% R when a typical clear conformal polymeric coating wassprayed and cured thereon, and the percent transmission correspondinglydecreased. Thus, if an ISI stack is to be used as a second surfacereflector on a prism shape and then in turn is to be conformal coatedfor protection as described above, then the layer thicknesses of the ISIstack should be adjusted, as known in the optical modeling arts, tocompensate for the addition of the clear optical protecting massive film(massive relative to the thickness of the ISI stack layers).

As an alternative to directly coating the likes of a silicon-basedtransflector or an ISI transflector directly onto the second surface ofa ground, clear-glass prismatic shape, the transflector coating orcoatings can be deposited onto a flat thin glass shape that is thenadhered to/laminated to the glass second surface of the prism shape,such as is disclosed in U.S. patent application Ser. No. 10/993,302,filed Nov. 19, 2004, now U.S. Pat. No. 7,338,177, which is herebyincorporated herein by reference in its entirety (and with thetransflector coating(s) sandwiched between the two glass substrates).This has the advantage that the transflector coating(s) are protectedagainst physical damage and/or environmental degradation (including edgeattack) by the extra glass substrate, and that large stock sheets ofthin glass can be coated from which interior mirror shapes can be cutlater to match the particular prism part to be laminated to.

The likes of an autoclave or a vacuum/heat-assisted technique may beused to adhere the flat transflector-coated shape to the second surfaceof the clear prism part [such as by placing the uncoated prism shapeonto a hotplate with its second surface up, placing a flexible sheet ofPVB or silicone onto the second surface, juxtaposing the cut flattransflector-coated glass shape onto the flexible polymeric sheet withthe coated surface downward, pulling a rubber flexible cover over thissandwich (or placing the sandwich in a vacuum bag), drawing down avacuum so as to remove air and compress the parts together, and heatingto laminate and secure permanently]. Alternatively, the rear flat secondtransflector-coated shape may be adhered to the second-surface of thefront prism-shaped element via a seal as is used in EC cellconstructions, and the interpane gap may be left unfilled or filled withthe likes of a solvent, such as propylene carbonate or a solid film suchas a plasticized urethane or the like.

Also, large sheets of, for example, about 2 mm thick or thereabouts,coated flat transflective reflector-coated mirror panes can bepurchased. Such sheets or shapes can be bent or cut to the desired shapeor form to suit the exterior mirror shape desired, and may be heated andbent to the desired curvature or form so that the shapes may be suitablefor use in exterior mirror assemblies. The glass sheets may be purchasedas coated sheets such as those described above. The mirror elements maycomprise prismatic DOD substrates, and may utilize aspects described inU.S. patent application Ser. No. 10/993,302, filed Nov. 19, 2004, nowU.S. Pat. No. 7,338,177, which is hereby incorporated herein byreference in its entirety. Optionally, a transflective CAZ coating stackor a transflective ISI coating stack or the like may be used as a fourthsurface transflective reflector in an electrochromic mirror element oras a first or second surface of a single substrate exterior mirrorassembly.

Optionally, the transflective mirror reflector, such as for asilicon-based transflective prismatic interior mirror element or a flator bent silicon-based exterior transflective mirror element, may besputter coated in a vacuum deposition process using an aluminum-dopedsilicon target or the like (such as utilizing aspects described in U.S.patent application Ser. No. 11/021,065, filed Dec. 23, 2004, now U.S.Pat. No. 7,255,451, which is hereby incorporated herein by reference inits entirety). Alternatively, the mirror reflector may be formed bychemical deposition or chemical vapor deposition or pyrolitic depositionon the glass surface. Optionally, the silicon-based transflective mirrorreflector may be formed by deposition onto the glass surface at theglass float-line itself when the glass ribbon is first being formed fromthe molten glass raw materials (where the red-hot molten glass exitingthe glass furnace is floated onto a tin bath and where the coatingmaterials or gasses or precursors are blown onto the red hot glassribbon as it first forms while it exits the tin bath and while it isstill in a very hot condition to form the transflective coatings on theglass surface).

Optionally, for example, a driver-side mirror may comprise anelectro-optic mirror element (such as a driver-side flat electrochromicelectrically variable reflectance mirror element, preferably atransflective, display-on-demand flat electrochromic electricallyvariable reflectance mirror element, and most preferably of flush orframeless construction and utilizing a reflective border band), and thepassenger-side mirror may comprise a non-electro-optic mirror element(such as a passenger-side convex conventional fixed reflectance mirrorelement, preferably a transflective, display-on-demand fixed reflectancemirror element, and most preferably utilizing a reflective border bandto match that used on the corresponding driver-side mirror element, asdescribed herein). The driver-side electro-optic mirror element (thatpreferably comprises an electro-optic medium disposed between andsandwiched by a front transparent glass or plastic substrate and a rear,mirror reflector-coated transparent glass or plastic substrate) may havethe second surface of its front transparent substrate coated with atransparent electrically conductive coating (such as ITO or the like)and may have its third surface (the inward surface of its reartransparent substrate) also coated with a transparent conductive coating(such as ITO or the like) so that light passes therethrough, and mayhave a significantly visible light reflecting (preferably at least about60% R specularly reflecting there off; more preferably at least about65% R there off and most preferably at least about 70% R there off) andsubstantially visible light transmitting (preferably at least about 10%T there through; more preferably at least about 15% T there through andmost preferably at least about 20% T there through) transflective mirrorreflector on its fourth surface (the rearmost substrate of the EC cell)that, preferably, comprises a high optical refractive index elementalsemiconductor mirror coating, such as of silicon or doped-silicon (orgermanium or doped germanium), and most preferably comprises sputtercoated silicon or doped-silicon such as silicon-aluminum or the like,such as described above. Suitable high optical refractive indexelemental semiconductor mirror coatings such as of silicon ordoped-silicon (or germanium or doped germanium) and preferably having anindex of refraction of at least 3 and an optical thickness of at leastabout 275 angstroms are disclosed in U.S. Pat. Nos. 6,286,965;5,751,489; and 5,535,056, the entire disclosures of which are herebyincorporated by reference herein. The passenger-side non-electro-opticmirror element may comprise a bent glass shape or substrate with atransflective mirror reflector on its first or second surface that,preferably, comprises a high index semiconductor coating such as ofsilicon or doped-silicon (or germanium or doped germanium), and morepreferably comprises sputter coated silicon or doped-silicon such assilicon-aluminum or the like, and most preferably is selected to matchthe reflectance characteristic and visual appearance of the driver-sidemirror element's reflector. Optionally, both the driver-sideelectro-optic mirror element and the passenger-side non-electro-opticmirror element may include a metallic specularly reflecting perimeterborder band, such as a neutral reflecting perimeter band as describedabove, such as described above. Preferably, the driver-side mirrorelement has the perimeter band disposed on its second surface with theITO coating disposed over the second surface and over the perimeterband, and the passenger-side mirror element has the perimeter banddisposed on its second surface with the silicon or doped-silicon orsilicon-aluminum disposed over the second surface and over the perimeterband. Thus, the reflective perimeter bands of the driver andpassenger-side mirror elements may provide a generally cosmetic orvisual appearance match between the two mirrors as both might be viewed,for example, at a car dealership or in use on the road or in a parkinglot or the like.

Optionally, the interior mirror of the vehicle may comprise atransflective prismatic mirror element (such as with a transflectivemirror reflector comprising silicon coating or doped-silicon coating,such as a silicon-aluminum coating, disposed thereon) and a displayoperable to emit illumination or video images through the transflectiveinterior mirror element. The driver-side and/or passenger-side mirrorelement/assembly may include an independent EC controller or controlcircuit system (such as is disclosed in U.S. Pat. No. 5,659,423, theentire disclosure of which is hereby incorporated by reference herein)for independently controlling the driver-side (and/or passenger-side)electro-optic mirror element or, for example, the driver-sideindependent EC controller outboard at the exterior mirrorelement/assembly may also control an interior electro-optic mirrorelement if applicable. Optionally, the vehicle may have an interiorelectro-optic mirror that includes EC driver/circuitry/controllers forcontrolling the interior electro-optic mirror element and thedriver-side electro-optic mirror element (and even a passenger-sideelectro-optic mirror element if applicable). Also, compass-on-a-chipcircuitry as disclosed herein may be included in either or both of theexterior mirror assemblies, and the microprocessor or allied circuitryof such an exterior mirror-located compass-on-a-chip may also functionto control the reflectivity of an electro-optic mirror element, such asan independent exterior electrochromic side view mirror element or aninterior electrochromic rear view mirror element.

Where a video display screen is disposed behind a transflective interiorprismatic mirror element (for use as, for example, the video screen in avideo mirror/reversing or back-up camera application), the video screenor monitor (typically an LCD or OLED flat panel of about 2.5 inches toabout 3.5 inches diagonal dimension) may attach directly to the flatsecond surface of the interior prism mirror element, or preferably, maybe mounted at an angle thereto so as to compensate for the prism wedgeangle (typically about 4 degrees to about 4.75 degrees orthereabout—about 4.5 degrees being common) so as to mitigate anypotential double imaging/ghosting due to the angling of the firstsurface of the prism wedge from its second surface. For example, a clearoptical plastic block can be attached to the second surface of the prismand with its rear surface at an about 4.5 degree angle to its front(that contacts the second surface of the prism) and slanted so that therear surface of the optical plastic block runs generally parallel to thefront; first surface of the prism shape. Then, when the flat videoscreen element attaches to the rear surface of the block, it isorientated generally parallel with the front, first surface of the prismelement, and video images emitted by the video screen are generallyincident perpendicular to the prism's first surface and so video imagedouble-imaging and ghosting is reduced. As an alternative to a clearoptical block, a slanted mount can be used to hold the video screen atan angle to the second surface of the prism in order to achieve similarbenefit. Also, and optionally, a light control film such as 3M'sVikuiti™ Light Control Film can be placed in front of the video screenbetween it and the rear of the mirror element so as to mitigate washoutin high ambient viewing conditions such as a sunny day. Such lightcontrol films or louver films comprise a continuous matrix of parallelblack louvers embedded in the likes of a polycarbonate film/thin(typically less than 0.04 inches thick) plastic sheet that limitsviewing off axis of the direction of the louvers. For example, andtaking an example where the louvers are at a 0.00 degrees angle to avertical axis to the horizontal plane of the sheet (i.e., the louversare vertical to the horizontal plane of the sheet), light transmissionof light that impinges generally vertically to the horizontal plane ofthe sheet has an about 75% T transmission through the light controlsheet, whereas light that impinges at about 15 degrees to vertical hasonly about a 35% T transmission due to the vertical orientation of thelouvers, and light impinging or incident at an angle of about 30 degreesand above is largely cut-off by the louvers. 3M Vikuiti™ ALCF-P lightcontrol film can be used, having a louver angle of about 0 degrees (plusor minus 2 degrees), a viewing angle of about 60 degrees (plus or minus4 degrees) and a sheet thickness of about 0.021 inches (plus or minus0.003 inches). Alternately, 3M Vikuiti™ LCF-P light control film can beused, having a louver angle of about 0 degrees (plus or minus 8degrees), a viewing angle of about 60 degrees (plus or minus 8 degrees)and a sheet thickness of about 0.021 inches (plus or minus 0.003inches). Alternately, 3M Vikuiti™ LCF-P light control film can be used,having a louver angle of about 0 degrees (plus or minus 8 degrees), aviewing angle of about 60 degrees (plus or minus 8 degrees) and a sheetthickness of about 0.032 inches (plus or minus 0.005 inches). Should anangled block or mechanical angling of the video screen to the plane ofthe rear of the mirror element be used, then the light control film maybe similarly angled if the louver angle is at about 0 degrees (such asby placing it between the video screen and the angled rear surface ofthe optical block attached to the rear, second surface of the prismaticmirror element). If no angling is used for the video screen with respectto the back of the transflective mirror element (such as a prismatictransflective mirror element or an electrochromic transflective mirrorelement), then the Vikuiti™ Light Control Film can be placed between thevideo screen and the second surface of the prism to which it is mounted.Note that if moiré patterns are seen with such light control films, thefilm may be slightly angled to mitigate this.

Optionally, an exterior mirror reflective element of the presentinvention may be used in a vehicle equipped with a transflectiveinterior prismatic mirror element such as is disclosed in U.S. patentapplication Ser. No. 10/993,302, filed Nov. 19, 2004, and published Jun.23, 2005 as U.S. Publication No. US 2005/0134983, now U.S. Pat. No.7,338,177, the entire disclosure of which is hereby incorporated byreference herein. A transflective prismatic mirror element may be madeby first grinding clear glass prisms from about 6 mm to about 6.5 mm orso thick flat glass shapes, and then coating the non-ground surface ofthese clear glass shapes with a transflective mirror reflector, such asfor example, with a sputter-coater deposited ITO/silver orsilver-alloy/ITO transflective mirror reflector coating stack.Similarly, conventional transflective non-electro-optic transflectiveexterior mirror elements can be made by first cutting clear glass shapesfrom about 2 mm or so thick glass sheets, bending if desired, edgefinishing and then sputter coating the second surface (or lesspreferably the first surface) with a transflective doped-silicon mirrorreflector or with a transflective metal oxide/metal/metal oxidetransflective mirror reflector (such as ITO/silver/ITO orAZO/Ag-alloy/AZO) or with a transflective silver or silver alloy coatingor with a transflective aluminum or aluminum alloy coating [andoptionally environmentally protecting the second surface coating with aclear, light transmitting protectorant such as a lacquer or coating(although in regions behind the second surface of the transflectiveprism element where display may not be likely located, a non-lighttransmitting protecting means may be used)].

Optionally, the mirror assembly and/or reflective element assembly (suchas a transflective mirror reflective element) may include a photodiodeor phototransistor or a silicon-based photosensor or the like forsensing ambient light and/or glare at the reflective element.Optionally, the photosensor may comprise a silicon-based photosensor,such as the types available from Microsemi of Irvine, Calif., such as aMicrosemi 1973B photosensor, such as a LX 1973A or 1973B photosensorthat has a maximum dark current (at 50 degrees Centigrade) of less thanabout 7500 microLux, preferably less than about 5000 microLux, and morepreferably less than about 4000 microLux. Preferably, such a photosensor(which is arranged so as to be looking through the transflective mirrorreflector of the reflective element) operates in a closed loop control,such as is known in the art and such as is described in U.S. Pat. No.4,917,477, which is hereby incorporated herein by reference in itsentirety.

Optionally, the mirror assembly may accommodate other accessories orcircuitry or the like as well, such as a rain sensor or imaging deviceor the like. For example, the mirror assembly may include a mountingportion (such as the types described in U.S. patent application Ser. No.11/226,628, filed Sep. 14, 2005 (Attorney Docket DON01 P-1236); and/orU.S. provisional applications Ser. No. 60/692,113, filed Jun. 20, 2005;Ser. No. 60/677,990, filed May 5, 2005; Ser. No. 60/653,787, filed Feb.17, 2005; Ser. No. 60/642,227, filed Jan. 7, 2005; Ser. No. 60/638,250,filed Dec. 21, 2004; Ser. No. 60/624,091, filed Nov. 1, 2004, and Ser.No. 60/609,642, filed Sep. 14, 2004, which are all hereby incorporatedherein by reference in their entireties), and may include a rain sensoror the like and may position the rain sensor against the windshield,such as described in U.S. Pat. Nos. 6,250,148; 6,341,523; 6,516,664;6,968,736; and 6,824,281, and in U.S. patent application Ser. No.10/958,087, filed Oct. 4, 2004, now U.S. Pat. No. 7,188,963, which areall hereby incorporated herein by reference in their entireties.Optionally, the mirror assembly may include an imaging device, such asan imaging array sensor for imaging systems of the types described inU.S. Pat. Nos. 6,757,109; 6,717,610; 6,396,397; 6,201,642; 6,353,392;6,313,454; 6,396,397; 5,550,677; 5,670,935; 5,796,094; 5,877,897;6,097,023; and 6,498,620, and U.S. patent application Ser. No.09/441,341, filed Nov. 16, 1999, now U.S. Pat. No. 7,339,149; Ser. No.10/427,051, filed Apr. 30, 2003, now U.S. Pat. No. 7,038,577; and/orSer. No. 11/315,675, filed Dec. 22, 2005, now U.S. Pat. No. 7,720,580,and/or U.S. provisional application Ser. No. 60/638,687, filed Dec. 23,2004, which are all hereby incorporated herein by reference in theirentireties.

Optionally, the mirror assembly may be associated with variousaccessories or systems, such as, for example, a tire pressure monitoringsystem or a passenger air bag status or a garage door opening system ora telematics system or any other accessory or system of the mirrorassembly or of the vehicle or of an accessory module or console of thevehicle, such as an accessory module or console of the types describedin U.S. Pat. Nos. 6,690,268; 6,672,744; 6,386,742; and 6,124,886, and/orU.S. patent application Ser. No. 10/739,766, filed Dec. 18, 2003, nowU.S. Pat. No. 6,877,888; and/or Ser. No. 10/355,454, filed Jan. 31,2003, now U.S. Pat. No. 6,824,281, and/or PCT Application No.PCT/US03/03012, filed Jan. 31, 2003 by Donnelly Corporation for VEHICLEACCESSORY MODULE, and/or PCT Application No. PCT/US03/40611, filed Dec.19, 2003 by Donnelly Corporation for ACCESSORY SYSTEM FOR VEHICLE,and/or PCT Application No. PCT/US04/15424, filed May 18, 2004 byDonnelly Corporation et al. for MIRROR ASSEMBLY FOR VEHICLE, which arehereby incorporated herein by reference in their entireties.

Optionally, the mirror assembly may support one or more otheraccessories or features, such as one or more electrical or electronicdevices or accessories. For example, illumination sources or lights,such as map reading lights or one or more other lights or illuminationsources, such as illumination sources of the types disclosed in U.S.Pat. Nos. 6,690,268; 5,938,321; 5,813,745; 5,820,245; 5,673,994;5,649,756; 5,178,448; 5,671,996; 4,646,210; 4,733,336; 4,807,096;6,042,253; 6,971,775; and/or 5,669,698, and/or U.S. patent applicationSer. No. 10/054,633, filed Jan. 22, 2002, now U.S. Pat. No. 7,195,381;and/or Ser. No. 10/933,842, filed Sep. 3, 2004, now U.S. Pat. No.7,249,860, which are hereby incorporated herein by reference in theirentireties, may be included in the mirror assembly. The illuminationsources and/or the circuit board may be connected to one or more buttonsor inputs for activating and deactivating the illumination sources.Optionally, the mirror assembly may also or otherwise include otheraccessories, such as microphones, such as analog microphones or digitalmicrophones or the like, such as microphones of the types disclosed inU.S. Pat. Nos. 6,243,003; 6,278,377; and/or 6,420,975, and/or in U.S.patent application Ser. No. 10/529,715, filed Mar. 30, 2005, now U.S.Pat. No. 7,657,052, and in PCT Application No. PCT/US03/308877, filedOct. 1, 2003 by Donnelly Corp. et al. for MICROPHONE SYSTEM FOR VEHICLE.Optionally, the mirror assembly may also or otherwise include otheraccessories, such as a telematics system, speakers, antennas, includingglobal positioning system (GPS) or cellular phone antennas, such asdisclosed in U.S. Pat. No. 5,971,552, a communication module, such asdisclosed in U.S. Pat. No. 5,798,688, a voice recorder, a blind spotdetection and/or indication system, such as disclosed in U.S. Pat. Nos.5,929,786 and/or 5,786,772, and/or U.S. patent application Ser. No.10/427,051, filed Apr. 30, 2003, now U.S. Pat. No. 7,038,577; and/orSer. No. 11/315,675, filed Dec. 22, 2005; and/or Ser. No. 10/209,173,filed Jul. 31, 2002, now U.S. Pat. No. 6,882,287; and/or U.S.provisional applications Ser. No. 60/638,687, filed Dec. 23, 2004; Ser.No. 60/696,953, filed Jul. 6, 2006; and/or Ser. No. 60/784,570, filedMar. 22, 2006, transmitters and/or receivers, such as for a garage dooropener or a vehicle door unlocking system or the like (such as a remotekeyless entry system), a digital network, such as described in U.S. Pat.No. 5,798,575, a high/low headlamp controller, such as a camera-basedheadlamp control, such as disclosed in U.S. Pat. Nos. 5,796,094 and/or5,715,093, a memory mirror system, such as disclosed in U.S. Pat. No.5,796,176, a hands-free phone attachment, an imaging system orcomponents or circuitry or display thereof, such as an imaging and/ordisplay system of the types described in U.S. Pat. Nos. 6,690,268 and6,847,487; and/or U.S. provisional applications Ser. No. 60/614,644,filed Sep. 30, 2004; Ser. No. 60/618,686, filed Oct. 14, 2004; Ser. No.60/628,709, filed Nov. 17, 2004; Ser. No. 60/644,903, filed Jan. 11,2005; Ser. No. 60/667,049, filed Mar. 31, 2005; and/or U.S. patentapplication Ser. No. 11/105,757, filed Apr. 14, 2005, now U.S. Pat. No.7,526,103; and/or Ser. No. 11/239,980, filed Sep. 30, 2005 (AttorneyDocket MAG04 P-1238), a slide out or extendable/retractable video deviceor module, such as described in U.S. patent application Ser. No.10/538,724, filed Jun. 13, 2005; and/or Ser. No. 11/284,543, filed Nov.22, 2005, now U.S. Pat. No. 7,370,983, U.S. provisional applicationsSer. No. 60/630,061, filed Nov. 22, 2004; and/or Ser. No. 60/667,048,filed Mar. 31, 2005; and/or PCT Application No. PCT/US03/40611, filedDec. 19, 2003, a video device for internal cabin surveillance (such asfor sleep detection or driver drowsiness detection or the like) and/orvideo telephone function, such as disclosed in U.S. Pat. Nos. 5,760,962and/or 5,877,897, a remote keyless entry receiver, a scat occupancydetector, a remote starter control, a yaw sensor, a clock, a carbonmonoxide detector, status displays, such as displays that display astatus of a door of the vehicle, a transmission selection (4wd/2wd ortraction control (TCS) or the like), an antilock braking system, a roadcondition (that may warn the driver of icy road conditions) and/or thelike, a trip computer, a tire pressure monitoring system (TPMS) receiver(such as described in U.S. Pat. Nos. 6,124,647; 6,294,989; 6,445,287;6,472,979; and/or 6,731,205; and/or U.S. patent application Ser. No.11/232,324, filed Sep. 21, 2005, now U.S. Pat. No. 7,423,522; and/orU.S. provisional application Ser. No. 60/611,796, filed Sep. 21, 2004),and/or an ONSTAR® system and/or any other accessory or circuitry or thelike (with all of the above-referenced patents and PCT and U.S. patentapplications being commonly assigned to Donnelly Corporation, and withthe disclosures of the referenced patents and patent applications beinghereby incorporated herein by reference in their entireties).

Optionally, the accessory module and/or mirror assembly may accommodateother accessories or circuitry or the like as well, such as a rainsensor or imaging device or the like. For example, the mirror assemblymay include a mounting portion (such as the types described in U.S.patent application Ser. No. 11/226,628, filed Sep. 14, 2005 (AttorneyDocket DON01 P-1236); and/or U.S. provisional applications Ser. No.60/692,113, filed Jun. 20, 2005; Ser. No. 60/677,990, filed May 5, 2005;Ser. No. 60/653,787, filed Feb. 17, 2005; Ser. No. 60/642,227, filedJan. 7, 2005; Ser. No. 60/638,250, filed Dec. 21, 2004; Ser. No.60/624,091, filed Nov. 1, 2004; Ser. No. 60/609,642, filed Sep. 14,2004; and/or Ser. No. 60/729,430, filed Oct. 21, 2005, which are allhereby incorporated herein by reference in their entireties), and mayinclude a rain sensor or the like and may position the rain sensoragainst the windshield, such as described in U.S. Pat. Nos. 6,250,148;6,341,523; 6,516,664; 6,968,736; and 6,824,281, and in U.S. patentapplication Ser. No. 10/958,087, filed Oct. 4, 2004, now U.S. Pat. No.7,188,963, which are all hereby incorporated herein by reference intheir entireties. Optionally, the mirror assembly may include an imagingdevice, such as an imaging array sensor for imaging systems of the typesdescribed in U.S. Pat. Nos. 6,757,109; 6,717,610; 6,396,397; 6,201,642;6,353,392; 6,313,454; 6,396,397; 5,550,677; 5,670,935; 5,796,094;5,877,897; 6,097,023; and 6,498,620, and U.S. patent application Ser.No. 09/441,341, filed Nov. 16, 1999, now U.S. Pat. No. 7,339,149; Ser.No. 10/427,051, filed Apr. 30, 2003, now U.S. Pat. No. 7,038,577; and/orSer. No. 11/315,675, filed Dec. 22, 2005, now U.S. Pat. No. 7,720,580,and/or U.S. provisional application Ser. No. 60/638,687, filed Dec. 23,2004, which are all hereby incorporated herein by reference in theirentireties.

Optionally, the mirror assembly may include one or more otheraccessories at or within the mirror casing, such as one or moreelectrical or electronic devices or accessories, such as antennas,including global positioning system (GPS) or cellular phone antennas,such as disclosed in U.S. Pat. No. 5,971,552, a communication module,such as disclosed in U.S. Pat. No. 5,798,688, a blind spot detectionsystem, such as disclosed in U.S. Pat. Nos. 5,929,786 and/or 5,786,772,transmitters and/or receivers, such as a garage door opener or the like,a digital network, such as described in U.S. Pat. No. 5,798,575, ahigh/low headlamp controller, such as disclosed in U.S. Pat. Nos.5,796,094 and/or 5,715,093, a memory mirror system, such as disclosed inU.S. Pat. No. 5,796,176, a hands-free phone attachment, a video devicefor internal cabin surveillance and/or video telephone function, such asdisclosed in U.S. Pat. Nos. 5,760,962 and/or 5,877,897, a remote keylessentry receiver, lights, such as map reading lights or one or more otherlights or illumination sources, such as disclosed in U.S. Pat. Nos.6,690,268; 5,938,321; 5,813,745; 5,820,245; 5,673,994; 5,649,756;5,178,448; 5,671,996; 4,646,210; 4,733,336; 4,807,096; 6,042,253; and/or5,669,698, and/or U.S. patent application Ser. No. 10/054,633, filedJan. 22, 2002, now U.S. Pat. No. 7,195,381; Ser. No. 10/745,056, filedDec. 22, 2003, now U.S. Pat. No. 6,971,775; and/or Ser. No. 10/933,842,filed Sep. 3, 2004, now U.S. Pat. No. 7,249,860, microphones, such asdisclosed in U.S. Pat. Nos. 6,243,003; 6,278,377; and/or 6,420,975;and/or U.S. patent application Ser. No. 10/529,715, filed Mar. 30, 2005,now U.S. Pat. No. 7,657,052; and/or PCT Application No. PCT/US03/30877,filed Oct. 1, 2003, speakers, antennas, including global positioningsystem (GPS) or cellular phone antennas, such as disclosed in U.S. Pat.No. 5,971,552, a communication module, such as disclosed in U.S. Pat.No. 5,798,688, a voice recorder, a blind spot detection system, such asdisclosed in U.S. Pat. Nos. 5,929,786 and/or 5,786,772, and/or U.S.patent application Ser. No. 10/427,051, filed Apr. 30, 2003, now U.S.Pat. No. 7,038,577; Ser. No. 11/315,675, filed Dec. 22, 2005; and Ser.No. 10/209,173, filed Jul. 31, 2002, now U.S. Pat. No. 6,882,287; and/orU.S. provisional application Ser. No. 60/638,687, filed Dec. 23, 2004,transmitters and/or receivers, such as for a garage door opener or avehicle door unlocking system or the like (such as a remote keylessentry system), a digital network, such as described in U.S. Pat. No.5,798,575, a high/low headlamp controller, such as a camera-basedheadlamp control, such as disclosed in U.S. Pat. Nos. 5,796,094 and/or5,715,093, a memory mirror system, such as disclosed in U.S. Pat. No.5,796,176, a hands-free phone attachment, an imaging system orcomponents or circuitry or display thereof, such as an imaging and/ordisplay system of the types described in U.S. Pat. Nos. 6,690,268 and6,847,487; and/or U.S. provisional applications Ser. No. 60/614,644,filed Sep. 30, 2004; Ser. No. 60/618,686, filed Oct. 14, 2004; Ser. No.60/628,709, filed Nov. 17, 2004; Ser. No. 60/644,903, filed Jan. 11,2005; Ser. No. 60/667,049, filed Mar. 31, 2005; and/or U.S. patentapplication Ser. No. 11/105,757, filed Apr. 14, 2005, now U.S. Pat. No.7,526,103, a video device for internal cabin surveillance (such as forsleep detection or driver drowsiness detection or the like) and/or videotelephone function, such as disclosed in U.S. Pat. Nos. 5,760,962 and/or5,877,897, a remote keyless entry receiver, a seat occupancy detector, aremote starter control, a yaw sensor, a clock, a carbon monoxidedetector, status displays, such as displays that display a status of adoor of the vehicle, a transmission selection (4wd/2wd or tractioncontrol (TCS) or the like), an antilock braking system, a road condition(that may warn the driver of icy road conditions) and/or the like, atrip computer, a tire pressure monitoring system (TPMS) receiver (suchas described in U.S. Pat. Nos. 6,124,647; 6,294,989; 6,445,287;6,472,979; and/or 6,731,205; and/or U.S. patent application Ser. No.11/232,324, filed Sep. 21, 2005, now U.S. Pat. No. 7,423,522; and/orU.S. provisional application Ser. No. 60/611,796, filed Sep. 21, 2004),and/or an ONSTAR® system, a compass, such as disclosed in U.S. Pat. Nos.5,924,212; 4,862,594; 4,937,945; 5,131,154; 5,255,442; and/or 5,632,092,and/or U.S. patent application Ser. No. 10/456,599, filed Jun. 6, 2003,now U.S. Pat. No. 7,004,593; and/or Ser. No. 11/305,637, filed Dec. 16,2005, now U.S. Pat. No. 7,329,013, and/or any other accessory orcircuitry or the like (with all of the above-referenced patents and PCTand U.S. patent applications being commonly assigned to DonnellyCorporation, and with the disclosures of the referenced patents andpatent applications being hereby incorporated herein by reference intheir entireties).

Optionally, a display of driver performance or aggressiveness or thelike can be included at the interior mirror assembly or at a windshieldelectronics module that utilizes data from the likes of the SmartCenterdeveloped by and available from Drive Diagnostics Ltd of Tel Aviv,Israel (see www.drivediagnostics.com). DriveDiagnostics' SafetyCentercomprises sensors that monitor moves and maneuvers the vehicle makes bymeasuring the forces on the car and software that identifies themaneuvers and produces a ‘driver behavior’ report. The system also canhave a GPS location device that measures the speed at which the car isbeing driven, rather than hooking up to the car's own speedometer. Asdisclosed in U.S. Pat. Publication No. 20050131597 (published Jun. 16,2005 based on an U.S. patent application Ser. No. 10/894,345, filed Jul.20, 2004, the entire disclosure of which is hereby incorporated byreference herein), the system and method analyzes and evaluates theperformance and attitude of a motor vehicle driver. A raw data streamfrom a set of vehicle sensors is filtered to eliminate extraneous noise,and then parsed to convert the stream into a string of driving eventprimitives. The string of driving events is then processed by apattern-recognition system to derive a sequence of higher-level drivingmaneuvers.

Driving maneuvers include such familiar procedures as lane changing,passing, and turning and braking. Driving events and maneuvers arequantified by parameters developed from the sensor data. The parametersand timing of the maneuvers can be analyzed to determine skill andattitude factors for evaluating the driver's abilities and safetyratings. The rendering of the data into common driving-related conceptsallows more accurate and meaningful analysis and evaluation than ispossible with ordinary statistical threshold-based analysis.

As soon as aggressive or dangerous driving is detected, real time alertsare presented to the driver in the car (such as by a transflectivedisplay at the interior mirror or by another mirror-located display) andoptionally, a parent can be notified via SMS messaging, mail or voicemail or a report can be sent to the car owner via a regular report (forexample, for General Motors vehicles equipped with an ONSTAR® telematicssystems, the monthly ONSTAR® e-mail report sent to subscribers caninclude a report on driver safety/“aggressiveness” and on the impactsuch has on fuel economy. SafetyCenter builds driver specific profilesand points directly at attitude and skill deficiencies that have to becorrected. Using user-friendly web interface, and as an example, both aparent and a young driver can get a better understanding of a driver'sbehavior and what has to be done in order to turn a young driver into askilled and responsible driver.

To achieve this, a compact unit can be installed, for example, in theinterior mirror housing or on a pod attaching to the interior mirrormount (so it is fixedly mounted) that may link into an in-car datalogging/analysis system and/or can link into the on-board ONSTAR® orsimilar system so that GPS data and driver behavior data may beregularly broadcast to the external ONSTAR® or similar telematics serverfor recording/compilation/analysis and reporting back to thedriver/owner/subscriber/insurance agency. The unit mounted at or in theinterior mirror assembly/windshield electronics module may comprise itsown set of sensors, GPS modem and GPS unit. The sensors in such a unitcan measure the forces impacting the vehicle and provide preciseinformation about each maneuver the driver performs. Each maneuver canbe evaluated on both attitude and skill parameters. This high resolutiondetection enables full visibility of driver behavior. Once aggressive ordangerous driving is detected, the information is sent real-time to anexternal server (such as the ONSTAR® server) or can be processed in-car;the data is analyzed and driver specific reports describing the driver'sbehavior are generated and can be reported/displayed to the driver suchas via a transflective video interior mirror display. The displayed datacan provide information and prescriptive guidance to driver while he/sheis driving and can alert if the driving pattern suggestrisky/aggressive/unsafe driving and/or a driving pattern (faststarts/heavy stops) likely to reduce fuel efficiency.

Typically, such a system utilizes a PCB or similar circuit elementequipped with a 3-axis accelerometer or the like. Such a PCB could byaccommodated in the interior mirror assembly (or in an attachmentthereto) or in a windshield electronics module. Thus, a display may beplaced at or about the interior mirror of the vehicle mirror that feedsback to the driver his/her driver “aggressiveness” performance and tiesthis to fuel economy and/or safety, and preferably is athru-the-mirror-reflector “display-on-demand” mirror display. Also,information from a forward facing video sensor (such as a lane departurewarning video sensor or the likes of MobilEye's EyeQ video-based objectdetection sensing system) or of a video camera monitoring the driver'sface/eyes to detect driver drowsiness can be combined/fused withDriveDiagnostic's “see how you drive” capability, thus making theassessment of aggressiveness tie into road type/conditions and weatherconditions (what might not be aggressive driving on a clear day might behazardous if it is snowing or foggy or at night or on a crowded roadcompared to a road with little traffic or on a wide road versus a narrowroad) and make the diagnosis dynamic to road/weather conditions, and ifa driver drowsiness is included, to how alert the driver appears to be.Packaging the electronics and/or the display (preferably a dynamicdisplay and most preferably a display that ties in fuel economy todriver aggressiveness/behavior) in a windshield electronics module (WEM)or in (or at) an interior mirror assembly has several benefits, andparticularly in a vehicle equipped with a telematics system (such asONSTAR®) where the likes of GPS and 3-axis accelerometers may already beon board and where the interior mirror already serves as a human-machineinterface or HMI (for example, microphone and button actuation) for thetelematics system. Also, the mirror-mounted or WEM-mounted display mayalert the driver if his or her driving habits are being reportedunfavorably to the driver's insurance company and thus possiblydegrading the ranking and reduction in premium awarded by the insurer inorder to entice less-aggressive and hence safer driving. For example, a“green-yellow-red” background or indicia may be utilized on the displayto convey to the driver the ranking being reported.

Optionally, the mirror assembly of the present invention comprise aninterior or exterior rearview mirror assembly and may include acompass-on-a-chip with electrochromic circuitry, such as described inU.S. patent application Ser. No. 11/226,628, filed Sep. 14, 2005(Attorney Docket DON01 P-1236); and/or Ser. No. 11/201,661, filed Aug.11, 2005, now U.S. Pat. No. 7,480,149, which are hereby incorporatedherein by reference in their entireties. For example, an exterior mirrorassembly may include a compass-on-a-chip, preferably with electrochromiccircuitry, such as for an independent outside electrochromic mirrordrive, such as by utilizing aspects described in U.S. Pat. No.5,659,423, which is hereby incorporated herein by reference in itsentirety. Optionally, the driver-side exterior mirror may comprise anelectro-optic minor element (such as an electrochromic mirror element)and the passenger-side exterior mirror may comprise a non-electro-opticmirror element, with the driver-side mirror having an independentelectrochromic minor drive and a compass-on-a-chip and electrochromiccircuitry. Optionally, the interior rearview mirror assembly maycomprise an electro-optic mirror element and may have an independentelectrochromic mirror drive or may be driven by the electrochromicmirror drive of the driver-side electro-optic mirror.

Optionally, the minor assembly may be utilized with a video slide-outmirror, such as the types described in PCT Application No.PCT/US03/40611, filed Dec. 19, 2003 by Donnelly Corp. et al. forACCESSORY SYSTEM FOR VEHICLE, and/or U.S. patent application Ser. No.10/538,724, filed Jun. 13, 2005 (Attorney Docket DON01 P-1123); and/orSer. No. 11/284,543, filed Nov. 22, 2005, now U.S. Pat. No. 7,370,983,and/or U.S. provisional applications Ser. No. 60/630,061, filed Nov. 22,2004; and Ser. No. 60/667,048, filed Mar. 31, 2005, which are herebyincorporated herein by reference in their entireties. Further, when sucha vehicle equipped with such a video mirror is also equipped with a sideviewing or front viewing or rear viewing sensor vision system (such asby utilizing a radar sensor or an ultrasonic sensor or a camera sensor(such as described in U.S. patent application Ser. No. 10/534,632, filedMay 11, 2005 (Attorney Docket DON01 P-1118); Ser. No. 11/239,980, filedSep. 30, 2005 (Attorney Docket DON01 P-1238); and/or Ser. No.11/315,675, filed Dec. 22, 2005, now U.S. Pat. No. 7,720,580, and/orU.S. provisional applications Ser. No. 60/628,709, filed Nov. 17, 2004;Ser. No. 60/614,644, filed Sep. 30, 2004; Ser. No. 60/618,686, filedOct. 14, 2004; Ser. No. 60/731,183, filed Oct. 28, 2005; Ser. No.60/765,797, filed Feb. 7, 2006; and/or Ser. No. 60/638,687, filed Dec.23, 2004, which are hereby incorporated herein by reference in theirentireties) to monitor an area adjacent the vehicle), the video screenmay automatically extend when such a sensor system detects the presenceof an obstacle and/or a human adjacent to the vehicle. Also, the videodisplay screen may extend in conjunction with a trailer-hitch monitoringsystem (such as the types described in U.S. patent application Ser. No.10/418,486, filed Apr. 18, 2003, now U.S. Pat. No. 7,005,974, which ishereby incorporated herein by reference in their entireties) and iconsand/or indicia and/or instructions may be created on the video imagedisplayed on the extended video screen of the video mirror to assist orguide the driver to hitch a trailer to the trailer hitch of the vehicle.

Optionally, the mirror assembly may include one or more user actuatableinputs or input devices or human machine interfaces. For example, theinputs or user interfaces may include buttons, such as are described inU.S. Pat. No. 6,501,387, which is hereby incorporated herein byreference in its entirety, or that include touch/proximity sensors suchas are disclosed in U.S. Pat. Nos. 6,001,486; 6,310,611; 6,320,282; and6,627,918, and U.S. patent application Ser. No. 09/817,874, filed Mar.26, 2001, now U.S. Pat. No. 7,224,324, and PCT Application No.PCT/US03/40611, filed Dec. 19, 2003, which are hereby incorporatedherein by reference in their entireties, or that include other types ofbuttons or switches, such as those described in U.S. patent applicationSer. No. 11/029,695, filed Jan. 5, 2005, now U.S. Pat. No. 7,253,723;and/or U.S. provisional applications Ser. No. 60/556,259, filed Mar. 25,2004; Ser. No. 60/553,517, filed Mar. 16, 2004; and Ser. No. 60/535,559,filed Jan. 9, 2004; and/or PCT Application No. PCT/US2004/015424, filedMay 18, 2004 by Donnelly Corp. et al. for MIRROR ASSEMBLY FOR VEHICLE,which are hereby incorporated herein by reference in their entireties,or that include fabric-made position detectors, such as are disclosed inU.S. Pat. Nos. 6,504,531; 6,501,465; 6,492,980; 6,452,479; 6,437,258;and 6,369,804, which are hereby incorporated herein by reference intheir entireties. The mirror assembly may comprise any other type ofswitches or buttons, such as touch or proximity sensing switches, suchas touch or proximity switches of the types described in U.S. patentapplication Ser. No. 11/021,065, filed Dec. 23, 2004, now U.S. Pat. No.7,255,451; Ser. No. 10/956,749, filed Oct. 1, 2004, now U.S. Pat. No.7,446,924; Ser. No. 10/933,842, filed Sep. 3, 2004, now U.S. Pat. No.7,249,860; Ser. No. 11/021,065, filed Dec. 23, 2004, now U.S. Pat. No.7,255,451; and/or Ser. No. 11/140,396, filed May 27, 2005, now U.S. Pat.No. 7,360,932; and/or U.S. provisional application Ser. No. 60/563,342,filed Apr. 19, 2004, which are hereby incorporated herein by referencein their entireties, or the inputs may comprise other types of buttonsor switches, such as those described in U.S. patent application Ser. No.11/029,695, filed Jan. 5, 2005, now U.S. Pat. No. 7,253,723; and/or U.S.provisional applications Ser. No. 60/553,517, filed Mar. 16, 2004; Ser.No. 60/535,559, filed Jan. 9, 2004; Ser. No. 60/690,401, filed Jun. 14,2005; Ser. No. 60/719,482, filed Sep. 22, 2005; and Ser. No. 60/749,423,filed Dec. 12, 2005, which are hereby incorporated herein by referencein their entireties, or such as fabric-made position detectors, such asthose described in U.S. Pat. Nos. 6,504,531; 6,501,465; 6,492,980;6,452,479; 6,437,258; and 6,369,804, which are hereby incorporatedherein by reference in their entireties. Other types of switches orbuttons or inputs or sensors may be incorporated to provide the desiredfunction, without affecting the scope of the present invention. Themanual inputs or user actuatable inputs or actuators may control oradjust or activate/deactivate one or more accessories or elements orfeatures. For touch sensitive inputs or applications or switches, themirror assembly or accessory module or input may, when activated,provide a positive feedback (such as activation of an illuminationsource or the like, or such as via an audible signal, such as a chime orthe like, or a tactile or haptic signal, or a rumble device or signal orthe like) to the user so that the user is made aware that the input wassuccessfully activated.

Optionally, the user inputs or buttons may comprise user inputs for agarage door opening system, such as a vehicle based garage door openingsystem of the types described in U.S. Pat. Nos. 6,396,408; 6,362,771;and 5,798,688, and/or U.S. patent application Ser. No. 10/770,736, filedFeb. 3, 2004, now U.S. Pat. No. 7,023,322; and/or U.S. provisionalapplications Ser. No. 60/502,806, filed Sep. 12, 2003 and Ser. No.60/444,726, filed Feb. 4, 2003, which are hereby incorporated herein byreference in their entireties. The user inputs may also or otherwisefunction to activate and deactivate a display or function or accessory,and/or may activate/deactivate and/or commence a calibration of acompass system of the mirror assembly and/or vehicle. The compass systemmay include compass sensors and circuitry within the mirror assembly orwithin a compass pod or module at or near or associated with the mirrorassembly. Optionally, the user inputs may also or otherwise compriseuser inputs for a telematics system of the vehicle, such as, forexample, an ONSTAR® system as found in General Motors vehicles and/orsuch as described in U.S. Pat. Nos. 4,862,594; 4,937,945; 5,131,154;5,255,442; 5,632,092; 5,798,688; 5,971,552; 5,924,212; 6,243,003;6,278,377; 6,420,975; 6,946,978; and 6,477,464; and/or 6,678,614; and/orU.S. patent application Ser. No. 10/456,599, filed Jun. 6, 2003, nowU.S. Pat. No. 7,004,593; Ser. No. 10/645,762, filed Aug. 20, 2003, nowU.S. Pat. No. 7,167,796; and Ser. No. 10/964,512, filed Oct. 13, 2004,now U.S. Pat. No. 7,308,341; and/or PCT Application No. PCT/US03/40611,filed Dec. 19, 2003 by Donnelly Corporation et al. for ACCESSORY SYSTEMFOR VEHICLE, and/or PCT Application No. PCT/US03/308877, filed Oct. 1,2003 by Donnelly Corp. for MICROPHONE SYSTEM FOR VEHICLE, which are allhereby incorporated herein by reference in their entireties.

Optionally, the accessory module may utilize aspects of other accessorymodules or windshield electronics modules or the like, such as the typesdescribed in U.S. patent application Ser. No. 10/958,087, filed Oct. 4,2004, now U.S. Pat. No. 7,188,963; Ser. No. 10/456,599, filed Jun. 6,2003, now U.S. Pat. No. 7,004,593; and/or Ser. No. 11/201,661, filedAug. 11, 2005, now U.S. Pat. No. 7,480,149, and/or U.S. Pat. Nos.6,824,281; 6,690,268; 6,250,148; 6,341,523; 6,593,565; 6,428,172;6,501,387; 6,329,925; and 6,326,613, and/or in PCT Application No.PCT/US03/40611, filed Dec. 19, 2003 by Donnelly Corp. et al. forACCESSORY SYSTEM FOR VEHICLE, and/or Ireland pat. applications Ser. No.S2004/0614, filed Sep. 15, 2004; Ser. No. S2004/0838, filed Dec. 14,2004; and Ser. No. S2004/0840, filed Dec. 15, 2004, which are all herebyincorporated herein by reference in their entireties.

Changes and modifications to the specifically described embodiments maybe carried out without departing from the principles of the presentinvention, which is intended to be limited only by the scope of theappended claims as interpreted according to the principles of patentlaw.

1. A driver attitude detection system for a vehicle, said driverattitude detection system comprising: a forward facing imaging sensorfor capturing image data of a scene occurring forwardly of and in thedirection of forward travel of a vehicle equipped with said forwardfacing imaging sensor; at least one monitoring device for monitoring avehicle characteristic of the equipped vehicle, said vehiclecharacteristic comprising at least one of (a) vehicle speed, (b) vehicleacceleration, (c) vehicle orientation and (d) a vehicle maneuver; animage processor operable to process image data captured by said forwardfacing imaging sensor, wherein said image processor processes saidcaptured image data to determine at least one of (i) a drivingcondition, (ii) a driving pattern, (iii) a road condition and (iv) aweather condition; and a control, wherein said control, responsive atleast in part to image processing by said image processor of saidcaptured image data and responsive at least in part to said at least onemonitoring device, is operable to determine driver performance andgenerate a control output indicative of driver performance.
 2. Thedriver attitude detection system of claim 1, further comprising an alertdevice that is operable in response to said control output to provide analert of driver performance.
 3. The driver attitude detection system ofclaim 2, wherein said alert device comprises at least one of (a) adisplay device in the equipped vehicle for displaying information,indicative of driver performance for viewing by an occupant of theequipped vehicle, (b) a communication signal indicative of driverperformance communicated to a receiver remote from the equipped vehicle,and (c) a report generator for generating a report indicative of driverperformance.
 4. The driver attitude detection system of claim 1, whereinsaid driver attitude system, responsive to said control output,generates a report, said report providing a driver rating.
 5. The driverattitude detection system of claim 4, wherein said report iscommunicated via a telematics system of the equipped vehicle.
 6. Thedriver attitude detection system of claim 5, wherein said report iscommunicated to an insurance company.
 7. The driver attitude detectionsystem of claim 1, further comprising another imaging sensor, saidanother imaging sensor having a field of view that encompasses thedriver's head when the driver is normally operating the equippedvehicle, wherein said control, at least in part responsive to imageprocessing of image data captured by said another imaging sensor, isoperable to determine driver drowsiness.
 8. The driver attitudedetection system of claim 7, wherein said control, at least in partresponsive to image processing of image data captured by said anotherimaging sensor, is operable to determine driver performance.
 9. Thedriver attitude detection system of claim 1, wherein said at least onemonitoring device comprises a component of a global positioning system.10. The driver attitude detection system of claim 1, wherein said atleast one monitoring device comprises at least one of an accelerometer,a three-axis accelerometer and a speed sensor.
 11. The driver attitudedetection system of claim 1, wherein said control is operable todetermine a condition exterior of the equipped vehicle, and wherein saidcontrol is operable to determine driver performance based at least inpart on the determined condition.
 12. The driver attitude detectionsystem of claim 11, wherein said determined condition comprises at leastone of (a) a weather condition, (b) a lighting condition, (c) a trafficcondition and (d) a road condition.
 13. The driver attitude detectionsystem of claim 12, wherein said control is operable to determine thecondition exterior of the equipped vehicle based at least in part onimage processing of said captured image data.
 14. The driver attitudedetection system of claim 1, wherein said forward facing imaging sensorcomprises part of a driver assistance system of the equipped vehicle.15. The driver attitude detection system of claim 14, wherein saiddriver assistance system comprises a lane departure warning system ofthe equipped vehicle.
 16. The driver attitude detection system of claim1, wherein said forward facing imaging sensor is disposed at an interiorrearview mirror assembly of the equipped vehicle.
 17. The driverattitude detection system of claim 16, wherein said forward facingimaging sensor is disposed at a windshield electronics module of theequipped vehicle.
 18. The driver attitude detection system of claim 16,wherein said forward facing imaging sensor is disposed in said interiorrearview mirror assembly of the equipped vehicle.
 19. The driverattitude detection system of claim 1, wherein said driver attitudedetection system is associated with an interior rearview mirror assemblyof the equipped vehicle.
 20. The driver attitude detection system ofclaim 19, further comprising a display at said interior rearview mirrorassembly of the equipped vehicle, wherein said display displaysinformation indicative of driver performance.
 21. The driver attitudedetection system of claim 20, wherein said interior rearview mirrorassembly an electrochromic mirror reflective element having electricallyvariable reflectivity between a high reflectance state and a dimmedreflectance state, and wherein said electrochromic mirror reflectiveelement comprises a front substrate having a first surface and a secondsurface and a rear substrate having a third surface and a fourth surfacewith a mirror reflector established at said third surface of said rearsubstrate, and wherein a specularly reflecting indicia reflector islocally established at said second surface of said front substrate toform indicia at said reflective element.
 22. The driver attitudedetection system of claim 21, wherein said display is disposed behindsaid electrochromic mirror reflective element and, when operated, saiddisplay displays information that is viewable through said mirrorreflector for viewing by the driver of the equipped vehicle when thedriver is normally operating the equipped vehicle.
 23. A driver attitudedetection system for a vehicle, said driver attitude detection systemcomprising: a forward facing imaging sensor for capturing image data ofa scene occurring forwardly of and in the direction of forward travel ofa vehicle equipped with said forward facing imaging sensor, and whereinsaid forward facing imaging sensor comprises part of a driver assistancesystem of the equipped vehicle; wherein said forward facing imagingsensor is one of (a) disposed at a windshield electronics module of theequipped vehicle and (b) disposed in an interior rearview mirrorassembly of the equipped vehicle; an image processor operable to processimage data captured by said forward facing imaging sensor, wherein saidimage processor processes said captured image data to determine at leastone of (i) a driving condition, (ii) a driving pattern, (iii) a roadcondition and (iv) a weather condition; and a control, wherein saidcontrol, responsive at least in part to image processing by said imageprocessor of said captured image data, is operable to determine driverperformance and generate a control output indicative of driverperformance.
 24. The driver attitude detection system of claim 23,wherein said driver assistance system comprises a lane departure warningsystem of the equipped vehicle.
 25. The driver attitude detection systemof claim 23, further comprising at least one monitoring device formonitoring a vehicle characteristic of the equipped vehicle, saidvehicle characteristic comprising at least one of (a) vehicle speed, (b)vehicle acceleration, (c) vehicle orientation and (d) a vehiclemaneuver, wherein said control, responsive at least in part to said atleast one monitoring device, is operable to determine driver performanceand generate said control output.
 26. The driver attitude detectionsystem of claim 25, wherein said at least one monitoring devicecomprises at least one of an accelerometer, a three-axis accelerometerand a speed sensor.
 27. The driver attitude detection system of claim23, further comprising another imaging sensor, said another imagingsensor having a field of view that encompasses the driver's head whenthe driver is normally operating the equipped vehicle, wherein saidcontrol, at least in part responsive to image processing of image datacaptured by said another imaging sensor, is operable to determine driverdrowsiness, and wherein said control, at least in part responsive toimage processing of image data captured by said another imaging sensor,is operable to determine driver performance.
 28. The driver attitudedetection system of claim 23, wherein said control is operable todetermine driver performance for a determined condition exterior of theequipped vehicle, and wherein said determined condition comprises atleast one of (a) a weather condition, (b) a lighting condition, (c) atraffic condition and (d) a road condition.
 29. A driver attitudedetection system for a vehicle, said driver attitude detection systemcomprising: a forward facing imaging sensor for capturing image data ofa scene occurring forwardly of and in the direction of forward travel ofa vehicle equipped with said forward facing imaging Sensor, and whereinsaid forward facing imaging sensor comprises part of a driver assistancesystem of the equipped vehicle; wherein said forward facing imagingsensor is one of (a) disposed at a windshield electronics module of theequipped vehicle and (b) disposed in an interior rearview mirrorassembly of the equipped vehicle; an image processor operable to processimage data captured by said forward facing imaging sensor, wherein saidimage processor processes said captured image data to determine at leastone condition external to the equipped vehicle; and a control, whereinsaid control, responsive at least in part to image processing by saidimage processor of said captured image data, is operable to determinedriver performance and generate a control output indicative of driverperformance.
 30. The driver attitude detection system of claim 29,wherein said at least one condition external to the equipped vehiclecomprises at least one of (i) a driving condition, (ii) a lightingcondition, (iii) a road condition, (iv) a weather condition and (v) atraffic condition.
 31. The driver attitude detection system of claim 29,wherein said driver assistance system comprises a lane departure warningsystem of the equipped vehicle.
 32. The driver attitude detection systemof claim 29, further comprising another imaging sensor, said anotherimaging sensor having a field of view that encompasses the driver's headwhen the driver is normally operating the equipped vehicle, wherein saidcontrol, at least in part responsive to image processing of image datacaptured by said another imaging sensor, is operable to determine driverdrowsiness, and wherein said control, at least in part responsive toimage processing of image data captured by said another imaging sensor,is operable to determine driver performance.
 33. A driver attitudedetection system for a vehicle, said driver attitude detection systemcomprising: a forward facing imaging sensor for capturing image data ofa scene occurring forwardly of and in the direction of forward travel ofa vehicle equipped with said forward facing imaging sensor, and whereinsaid forward facing imaging sensor comprises part of a driver assistancesystem of the equipped vehicle; at least one monitoring device formonitoring a vehicle characteristic of the equipped vehicle, whereinsaid at least one monitoring device comprises at least one of (a) acomponent of a global positioning system, (b) an accelerometer, (c) athree-axis accelerometer and (d) a speed sensor; an image processoroperable to process image data captured by said forward facing imagingsensor; and a control, wherein said control, responsive at least in partto image processing by said image processor of said captured image dataand responsive at least in part to said at least one monitoring device,is operable to determine driver performance and generate a controloutput indicative of driver performance.
 34. The driver attitudedetection system of claim 33, wherein said forward facing imaging sensoris one of (a) disposed at a windshield electronics module of theequipped vehicle and (b) disposed in an interior rearview mirrorassembly of the equipped vehicle.
 35. The driver attitude detectionsystem of claim 34, wherein said vehicle characteristic monitored bysaid at least one monitoring device comprises at least one of (a)vehicle speed, (b) vehicle acceleration, (c) vehicle orientation and (d)a vehicle maneuver.
 36. The driver attitude detection system of claim33, wherein said image processor processes said captured image data todetermine at least one condition external to the equipped vehicle. 37.The driver attitude detection system of claim 33, further comprising analert device that is operable in response to said control output toprovide an alert of driver performance, and wherein said alert devicecomprises at least one of (a) a display device in the equipped vehiclefor displaying information indicative of driver performance for viewingby an occupant of the equipped vehicle, (b) a communication signalindicative of driver performance communicated to a receiver remote fromthe equipped vehicle, and (c) a report generator for generating a reportindicative of driver performance.